U.S. patent application number 14/055994 was filed with the patent office on 2014-02-13 for methods of making snack food products and products made thereby.
This patent application is currently assigned to Jamshid Ashourian. The applicant listed for this patent is Jamshid Ashourian. Invention is credited to Jamshid Ashourian, Laurie J. Keeler, Durward A. Smith.
Application Number | 20140044833 14/055994 |
Document ID | / |
Family ID | 37906868 |
Filed Date | 2014-02-13 |
United States Patent
Application |
20140044833 |
Kind Code |
A1 |
Ashourian; Jamshid ; et
al. |
February 13, 2014 |
METHODS OF MAKING SNACK FOOD PRODUCTS AND PRODUCTS MADE THEREBY
Abstract
Methods of making low-fat or fat free snack food products, and
products made according to the methods, in which food pieces are
subjected to enzyme and/or cation treatment and/or specific cooking
and/or drying techniques, to provide for snack food products having
the texture, flavor, and other characteristics of conventional
full-fat products.
Inventors: |
Ashourian; Jamshid; (Santa
Monica, CA) ; Keeler; Laurie J.; (Lincoln, NE)
; Smith; Durward A.; (Lincoln, NE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Jamshid Ashourian |
Deerfield |
IL |
US |
|
|
Assignee: |
Ashourian; Jamshid
Deerfield
IL
|
Family ID: |
37906868 |
Appl. No.: |
14/055994 |
Filed: |
October 17, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14054323 |
Oct 15, 2013 |
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14055994 |
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12090845 |
Jul 6, 2009 |
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PCT/US06/38963 |
Oct 4, 2006 |
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14054323 |
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60723880 |
Oct 4, 2005 |
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60820743 |
Jul 28, 2006 |
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Current U.S.
Class: |
426/52 |
Current CPC
Class: |
A23B 7/155 20130101;
A23V 2002/00 20130101; A23B 7/06 20130101; A23L 19/12 20160801;
A23L 19/18 20160801; A23L 19/03 20160801; A23L 19/09 20160801; A23L
5/15 20160801 |
Class at
Publication: |
426/52 |
International
Class: |
A23L 1/212 20060101
A23L001/212 |
Claims
1. A method of making a snack food product comprising, (a)
providing a plurality of cut or shaped food pieces; (b) exposing
the food pieces for about 0.5-5 minutes to a solution comprising an
effective amount of a starch-reducing enzyme; (c) thereafter
blanching the food pieces for a time sufficient to inactivate the
enzymes, wherein the food pieces have an initial moisture level
after the blanching step; and (d) reducing the initial moisture
level of the food pieces in the absence of frying in oil by cooking
the food pieces to about 200-400.degree. F. for about 0.5-20 min.,
to yield a snack food product containing up to about 15 wt-% fat
and having a final moisture level so that the snack food product
exhibits a characteristic of a snack food product produced by
frying a food piece in oil wherein the characteristic is selected
from the group consisting of texture, flavor, crispness,
crunchiness, color and appearance.
2. The method of claim 1, wherein the food pieces are cooked at
about 275-300.degree. F.
3. The method of claim 2, wherein the food pieces are cooked in a
dryer/oven providing an air velocity of about 500-10,000 feet per
minute.
4. The method of claim 1, wherein in step (d) the food pieces are
brought to a first temperature for a first time period to reduce
the initial moisture level to about 40-70% and thereafter bringing
the food pieces to a second temperature for a second time to yield
the snack food product.
5. The method of claim 4, wherein the second temperature is lower
than the first temperature.
6. The method of claim 5, wherein bringing the food pieces to the
first temperature for the first time period comprises cooking the
food pieces at a temperature of about 275-375.degree. F. for a time
of about 0.5 to about 14 minutes.
7. The method of claim 4, wherein bringing the food pieces to the
second temperature for the second time period comprises cooking the
food pieces to a temperature of about 300-325.degree. F. for a time
of about 6 to about 12 minutes.
8. The method of claim 1, wherein the snack food product has a
ratio of percent by weight of moisture to percent by weight of fat
of at least about 12:1.
9. The method of claim 1, wherein the snack food product has an
average force of fracture of less than or equal to 12 N, and an
average Young's modulus of equal to or greater than about 3.5
N/mm.
10. The method of claim 4, wherein the food pieces are cooled and
stored at ambient, refrigeration or freezer conditions after the
food pieces are brought to the first temperature for the first time
period, and before the food pieces are brought to the second
temperature for the second time period.
11. The method of claim 1, wherein the moisture content of the
resulting snack food product is about 0.5-10% by weight.
12. The method of claim 1, wherein the solution further comprises
one or more cations.
13. The method of claim 12, wherein the one or more cations are
selected from the group consisting of sodium salts, calcium salts,
magnesium salts, potassium salts, aluminum compounds and nitrogen
compounds.
14. The method of claim 13, wherein the one or more cations are
selected from the group consisting of NaCl, KCl, MgCl.sub.2, and
CaCl.sub.2.
15. The method of claim 12, wherein the one or more cations is
present in the solution at a concentration of about 0.1 to about 5%
by weight.
16. The method of claim 1 wherein the enzymes are one or more of
alpha amylase, beta amylase or amyloglucosidase.
17. The method of claim 16, wherein the one or more enzymes is
present in the solution at a concentration of about 0.1 to about 5%
by weight.
18. The method of claim 1, wherein the food pieces are exposed to
the solution for a time of about 1 to about 3 minutes.
19. The method of claim 2, wherein the food pieces are cooked in a
dryer/oven providing an air velocity of about 500-10,000 feet per
minute.
20. The method of claim 1, wherein said food is selected from the
group consisting of beets, zucchini, carrots, eggplant, apples,
pears, bananas, rutabaga, plantain, taro, okra, onions, parsnips,
yams, sweet potatoes, yucca, and potatoes.
21. The method of claim 1, wherein said cut food pieces are slices,
strips or sticks.
22. The method of claim 1, wherein said blanching comprises a wet
blanch.
23. The method of claim 22, wherein said wet blanch comprises
treating said cut food pieces in an aqueous solution at a
temperature of about 60.degree. C. to 120.degree. C., and for about
30 seconds to about 10 minutes.
24. The method of claim 23, wherein said wet blanch comprises
treating said cut food pieces in an aqueous solution at a
temperature of about 70.degree. C. to 100.degree. C., and for about
40 seconds to about 3 minutes.
25. The method of claim 1, wherein said blanching step comprises a
dry blanch.
26. The method of claim 1, that further comprises application of a
predetermined amount of digestible and/or synthetic oil to said
food pieces.
27. The method of claim 26, wherein said blanching step occurs in a
blanching medium comprising digestible and/or synthetic oil.
28. The method of claim 26, comprising applying a predetermined
amount of digestible and/or synthetic oil to the food pieces prior
to cooking the food pieces.
29. The method of claim 1, further comprising a step of (e)
applying a predetermined amount of digestible and/or synthetic fat
or oil to the snack food product.
30. The method of claim 26, wherein the fat content of the snack
food product is up to about 35 wt-%.
Description
[0001] This application is a continuation of U.S. patent
application Ser. No. 14/054,323, filed Oct. 15, 2013, which is a
continuation of U.S. patent application Ser. No. 12/090,845, filed
on Jul. 6, 2009, which is a U.S. National Stage Filing under 35
U.S.C. 371 from International Application No. PCT/US2006/038963,
filed Oct. 4, 2006, published in English as WO 2007/041679, which
claims the benefit of priority under 35 U.S.C. 119(e) to U.S.
Provisional Patent Ser. No. 60/723,880, filed Oct. 4, 2005, and to
U.S. Provisional Application Ser. No. 60/820,743, filed Jul. 28,
2006, all of which are incorporated herein by reference in their
entireties.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to methods of making
low-fat, fat free, or full-fat snack food products, and products
made according to the method, in which food pieces are subjected to
enzyme and/or cation treatment and/or specific cooking and/or
drying techniques, to provide for snack food products having the
texture, flavor, and other characteristics of conventional full-fat
products.
[0003] Snack food products typically are made by frying sliced
vegetable pieces in hot oil so that the moisture content of the
sliced food pieces is reduced to a very low level and fat content
is raised exponentially. Such products generally have a
characteristic crispness that adds significantly to its
organoleptic desirability. Fried potato or apple chips prepared
using conventional methods generally have a fat content from about
30 percent to about 40 percent by weight, a percentage of fat that
is considered by some to be unhealthy if these types of products
are broadly substituted for low-fat foods and consumption is
significant over time. While such products are accepted in the
marketplace, consumers' desire to lower their fat consumption,
limits this acceptance.
[0004] Furthermore, the conventional methods generally used,
require these foods to be fried at high temperatures that can
result in the production of potentially deleterious by-products.
Reports of such by-products in recent years have led to general
concerns about both fried and baked foods, especially those
containing high amounts of fats and carbohydrates. Reports of
acrylamide formation, generally in proportion to the degree of
browning of foods high in fats and carbohydrates, have raised
significant concerns within the food industry, the potential for
harmful effects of this particular processing by-product.
[0005] To address some of these concerns, efforts have been made to
reduce the amount of fat in such snack food products, and more
recently, to find ways to minimize formation of potentially
deleterious substances such as acrylamide and the like.
[0006] In recent years, "light" chips have been made using
synthetic oils/fat that is substantially non-digestible and
consequently non-absorbable by the human body, e.g. OLESTRA.TM..
These products have received limited acceptance due in part to
off-flavors perceived by some reports of detrimental
gastrointestinal side effects and an FDA requirement of a warning
label on such products, providing information that such fat
substitutes may cause gastrointestinal side effects such as loose
stools and abdominal cramping and/or the inhibition of absorption
of some nutrients.
[0007] While products such as potato and apple chips are typically
made using conventional frying methods, snack food products made
with other nutritionally beneficial vegetables and fruits such as
carrots, squash, parsnips, yuccas, pears, and the like have not
successfully entered the market substantially due to the lack of
proper processing methods.
[0008] There have been numerous efforts in the past to reduce the
amount of fat in snack foods such as potato chips.
[0009] Roan (U.S. Pat. No. 4,058,631) discloses a method of making
fried food in which raw food product is treated with an aqueous
solution of an enzyme, such as alpha amylase, for a period of time
sufficient for the enzyme to penetrate and coat the surface of the
food, and thereafter the food product is deep fried. Roan Indicates
that when the surface of a raw, starchy food product is coated with
an aqueous solution of alpha amylase prior to frying, less fat is
absorbed in the food during frying than occurs without the enzyme
treatment, and the flavor of the fried food is improved.
[0010] Dreher et al. (U.S. Pat. No. 4,756,916) discloses a process
for producing low oil potato chips comprising washing potato slices
with an aqueous solution, and applying oil to the washed slices to
coat the slices with oil. The oil-coated slices are arranged as a
monolayer on an endless conveyor belt, blanched at a temperature
between about 160.degree. F. and 212.degree. F., and then baked at
a high temperature of at least about 390.degree. F. but below the
smoke point of the oil, to partially dry the slices by reducing the
aqueous moisture content of the slices to about 10-20% by weight.
The partially dried slices then are further baked at a lower
temperature of about 290.degree.-320.degree. F. to finish drying
the slices by reducing the aqueous moisture content of the slices
to about 2% by weight or less, to produce a product having an oil
content of between about 10-25% by weight.
[0011] Laufer (U.S. Pat. No. 5,292,540) discloses a process for
preparing potato chips comprising the steps of washing potatoes to
remove foreign matter from the skin thereof, cutting the potato
into thin slices, baking the slices for a period of about six to
twelve minutes within a temperature range of about 250 to
500.degree. F., and heating the slices in a microwave oven for
about two to seven minutes.
[0012] Yamashita (U.S. Pat. No. 5,312,631) discloses a method for
preventing cut pieces of agricultural products from sticking to
each other during the steps of drying and cooking, which includes
washing the cut pieces with, or immersing the same in, a solution
of an amylolytic enzyme, or an acidic or alkaline aqueous solution.
The cut pieces are blanched prior to enzyme treatment.
[0013] Zussman (U.S. Pat. No. 5,370,898) discloses a cooking
process for food chip products that does not involve oil-based
cooking. Food slices are washed with water to remove extractable
surface starch, multi-layered, transported to an oven, and baked in
a fluidized bed of hot air or steam. The baking process is a
multi-step process, whereby the food slices are exposed to a higher
pressure in a first zone for several minutes to ensure that the
individual food pieces are separated. The pressure is then lowered
in a second zone for a second period of time. Similarly, in a third
zone the pressure is reduced for a predetermined period of time to
finish cooking the food products. Thereafter the chips are
air-dried or finished in a dryer.
[0014] Lewis et al. (U.S. Pat. No. 5,441,758) discloses the
preparation of low-fat or fat free potato chips or straws by a
process comprising slicing potatoes to form slices or straws,
blanching the sliced potato, and treating the slices during or
after blanching with a high temperature amylase enzyme to prevent
later sticking together of slices during processing. The slices are
thereafter dehydrated to a moisture content of 12% to 30%, and
thereafter toasted to about 2% moisture at a temperature of
140.degree. C. to 220.degree. C. The use of a high temperature
amylase is required so that the enzyme remains effective during
processing, and is not inactivated by the blanching step.
[0015] Petelle et al. (U.S. Pat. No. 5,470,600) discloses a method
of making fat-free potato chips, by initially cooking potato slices
in a three zone primary oven, by first radiant heating the slices
and then subjecting the slices to two successive stages of forced
air heating to reduce the moisture content of the slices to near a
final moisture content. Petelle et al. further discloses
independently controlling the time duration in each of the three
zones, simultaneously forcing the air into the top and bottom
surfaces of the slices in the primary oven to a near final moisture
content of about 15% by weight, independently controlling the time
duration of the slices in the dielectric heater to a final moisture
content of about 7% by weight using wavelengths of about 65.8 feet
at a frequency of about 15 mhz, and allowing the slices to
successively, increasingly pile up in the last two forced air
stages and the dielectric heating stage.
[0016] Benson at al. (U.S. Pat. No. 5,603,973) discloses a process
for making potato chips without the use of oil, wherein whole
potatoes are cut into discrete slice pieces which are washed to
remove starch or debris from the slice surfaces. The slices are
arranged in a single layer and the surface water is removed from
the slice surfaces by exposing them to blasts of air and suction.
Alternatively, the slices may be washed in warm water at a
temperature of about 130.degree. F. to preheat them. The slices are
transferred to a heated conveyor to enter an infrared zone for
exposure to high intensity infrared energy for a short period of
time, less than 25 seconds, effecting a blanching of the slices and
quenching of naturally-occurring deleterious enzyme action. In a
subsequent step, dry air is impinged upon the slices from above and
below to reduce the water content below 35% by weight. The slices
are accumulated in a multi-layer pack and dried in moving air until
moisture content has been obtained to a level on the order of 0.5%
to 2%.
[0017] Wiedersatz (U.S. Pat. No. 5,858,431) discloses a method for
preparing fat-free snack chips, comprising preparing slices of raw
food product, which are subjected to a high intensity air knife
arrangement to remove surface moisture, then exposed to a hot air
fluid bed impingement including multiple dual-zone hot air fluid
bed impingement ovens operating under different predetermined
conditions. In the preferred embodiment, the slices are exposed to
two dual-zone hot air fluid bed impingement ovens, the first oven
having a conveyor belt transporting slices through the oven at a
speed of 2.5 to 3.0 feet per minute and operating at 500 to
525.degree. F. (zone 1) and 450 to 500.degree. F. (zone 2), and the
second oven having a conveyor belt operating at a speed of 1.5 to
2.0 feet per second and at 350 to 400.degree. F. (zone 1) and 300
to 350.degree. F. (zone 2). The first impingement oven of the
preferred embodiment removes approximately 50 to 60 percent of the
moisture in each slice, while the second impingement oven of the
preferred embodiment removes approximately 20 to 30 percent of the
remaining moisture. The slices may then have oil and/or seasoning
applied thereto, and are passed to a combination microwave and hot
air dryer which removes entrained moisture without scorching the
chips.
[0018] Xu et al. (U.S. Patent Publication No. 2002/0004085)
discloses methods for producing a consumable product from potatoes,
comprising: (a) treating a potato substance with an effective
amount of one or more exogenous enzymes selected from the group
consisting of an amyloglucosidase, glucose oxidase, laccase,
lipase, maltogenic amylase, pectinase, pentosanase, protease, and
transglutaminase, and (b) processing the enzyme-treated potato
substance to produce a potato product. In one embodiment, blanching
of the potato substance may occur prior to enzyme treatment. The
processing step may include frying in oil or baking.
[0019] Despite the many advances in the processing of snacks and
chips, there nevertheless remains a need for improvements to these
products, and the processes for making them, characterized by
improved crispness, mouth feel and flavor properties, reduction of
fat content and overall improvement in nutritional profile,
including minimization of exposure to conditions that can result in
the formation of potentially deleterious by-products, all resulting
from processes that are feasible, efficient, manageable, and are
practically and economically scaleable for production at output
levels necessary for product commercialization in an adequately
fuel efficient production environment. There also remains a need
for eliminating the conventional deep frying processes that
traditionally have been used for the production of full-fat and
some reduced fat snack foods, and controlling the amount of fat in
such products to provide a predetermined amount. Further, there
remains a need for snack food products made from certain fruits
vegetables, nuts, grains and the like, or the healthier versions of
numerous currently available snack products, not previously
feasible to make and the methods for their production.
SUMMARY OF THE INVENTION
[0020] A first embodiment of the present invention is directed to a
method of making a snack food product comprising, [0021] (a)
providing a plurality of cut or shaped food pieces; [0022] (b)
exposing the food pieces to a solution comprising one or more
enzymes to coat the surface thereof; [0023] (c) thereafter
blanching the plurality of food pieces for a time sufficient to
inactivate any enzymes on the surface of the food pieces, wherein
the food pieces have an initial moisture level after the blanching
step; and [0024] (d) reducing the initial moisture level to a final
moisture level of about 0.5 to about 10% by weight.
[0025] A second embodiment of the present invention is directed to
a method of making a snack food product comprising, [0026] (a)
providing a plurality of cut or shaped food pieces; [0027] (b)
exposing the food pieces to a solution comprising one or more
cations to coat the surface thereof; [0028] (c) thereafter
blanching the plurality of food pieces for a time sufficient to
inactivate any enzymes on the surface of the food pieces, wherein
the food pieces have an initial moisture level after the blanching
step; and [0029] (d) reducing the initial moisture level to a final
moisture level of about 0.5 to about 10% by weight.
[0030] A third embodiment of the present invention is directed to a
method of making a snack food product comprising, [0031] (a)
providing a plurality of cut or shaped food pieces; [0032] (b)
blanching the plurality of food pieces for a time sufficient to
inactivate any enzymes on the surface of the food pieces, wherein
the food pieces have an initial moisture level after the blanching
step; and [0033] (c) reducing the initial moisture level to a final
moisture level of about 0.5 to about 10% by weight by exposing the
food pieces to a first moisture level reduction procedure which
reduces the initial moisture level to an intermediate moisture
level of about 10 to about 80% by weight, and thereafter exposing
the food pieces to a second moisture level reduction procedure
which reduces the intermediate moisture level to the final moisture
level. The second moisture level reduction procedure, among other
feasible procedures, may include frying the food pieces in an oil
or oil substitute.
[0034] A fourth embodiment of the present invention is directed to
a snack food product comprising cut or shaped food pieces, wherein
each of the food pieces has a predetermined fat content of less
than 1 to about 35% by weight, an average force of fracture of less
than or equal to 12 N, and an average Young's modulus of equal to
or greater than about 3.5 N/mm.
[0035] A fifth embodiment of the present invention is directed to a
method of making a snack food product comprising, [0036] (a)
providing a plurality of cut or shaped food pieces; [0037] (b)
blanching the plurality of food pieces, wherein the food pieces
have an initial moisture level after the blanching step; and [0038]
(c) reducing the initial moisture level to a final moisture level
of about 0.5 to about 10% by weight by drying the food pieces in
one step or multiple steps wherein at least one step is conducted
in a rotary dryer, a fluidized bed dryer, a vibrating fluidized bed
dryer and the like or combinations thereof while controlling the
temperature, air flow and movement of the food pieces to allow for
even and constant exposure of the food pieces to heat.
[0039] A sixth embodiment of the present invention is directed to a
method of making a snack food product comprising, [0040] (a)
providing a plurality of cut or shaped food pieces; [0041] (b)
blanching the plurality of food pieces, wherein the food pieces
have an initial moisture level after the blanching step; and [0042]
(c) reducing the initial moisture level to an intermediate moisture
level of about 10 to about 80% by weight while controlling the
temperature, air flow and movement of the food pieces to allow for
even and constant exposure of the food pieces to heat, and
thereafter exposing the food pieces to a second moisture level
reduction procedure which reduces the intermediate moisture level
to the final moisture level.
[0043] A seventh embodiment of the present invention is directed to
a method of making a snack food product comprising, [0044] (a)
providing a plurality of cut or shaped food pieces; [0045] (b)
thereafter blanching the plurality of food pieces for a time
sufficient to inactivate any enzymes on the surface of the food
pieces, wherein the food pieces have an initial moisture level
after the blanching step; and [0046] (c) reducing the initial
moisture level to a final moisture level of about 0.5 to about 10%
by weight in accordance with any of the aforementioned embodiments
herein, either (i) without the application of a solution comprising
enzymes or cations or (ii) by exposing the food pieces to a
solution comprising at least a combination of one or more enzymes
and one or more cations in any feasible manner to coat the surface
thereof.
[0047] A frying step and/or a drying step using a vacuum dryer, a
vacuum belt dryer, and the like can be inserted as a reducing step,
preferably the final drying step, in any of the aforementioned
embodiments.
[0048] An eighth embodiment of the present invention is snack food
products made from vegetables, fruits, nuts, grains and other
consumable ingredients, and any combination thereof, and the method
of their production, where the commercial production of such snack
foods, or the production of their healthier versions, were not
previously feasible.
[0049] Additional features of the invention can be understood in
reference to the accompanying descriptive matter in which there is
illustrated and described preferred embodiments of the present
invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0050] In preferred embodiments, the present invention provides a
snack food product processed in such a manner so as to provide a
plurality of cut or shaped food pieces that have a taste, texture
and/or appearance of conventionally produced products made by a
process including a step in which the food pieces are fried in oil
(typically at temperatures of greater than about 300.degree. F.).
Preferably, a snack food product prepared in accordance with the
present invention has at least one, preferably at least three,
preferably at least five, of the following attributes: a crisp
texture, a fat content of less than about 0.5% by weight, a
moisture content of greater than about 0.5% by weight, a ratio of
percent by weight of moisture to percent by weight of fat of at
least about 12, and the food pieces will fracture at less than or
equal to about 12 N and have an average Young's modulus of equal to
or greater than about 3.5 N/mm.
[0051] In yet another preferred embodiment the present invention
provides a snack food product and the method of its production
and/or cooking processed in such a manner so as to provide a
plurality of cut or shaped food pieces that (i) have a new and/or
unique taste, texture and/or appearance, or (ii) have less fat
and/or are considered as healthier versions of currently available
products, or (iii) have been made from vegetables, fruits, grains,
nuts, legumes or any other consumable ingredients and their
combination thereof where the production of such products were not
previously feasible due to lack proper production and/or cooking
methods.
[0052] Surprisingly, the present invention has been found to retain
the desired high quality, flavor, texture, appearance and consumer
acceptability of high-fat snacks, through certain desirable
treatment of the raw materials and subsequent cooking under
conditions that eliminates, optionally minimizes, and/or controls
the amount of contact with fats, such as oils or oil substitutes,
and limit the potential for producing potentially deleterious
by-products. Further, in contrast with known conventional frying
methods, the food pieces may be infused with a predetermined amount
of fat in a `totally controlled environment` during the production
process. In addition to being able to control the desired amount of
fat being infused into the products of present invention to an
exact amount, the present invention entirely eliminates the need
for utilizing pools of hot oils or oil substitutes, and
maintaining, filtering out, and, at last, in most cases, disposing
of the related fats used in the production process.
[0053] In addition, the present invention also eliminates the need
for using defatters in the production of relevant low-fat snack
food products.
[0054] The term "food pieces" is intended to include substantially
any foods. Preferably, the food pieces may be provided as cut or
shaped food pieces that can be shaped or reshaped directly from
their raw state. These foods include potato, beet, pumpkin, squash,
tomato, mushroom, zucchini, carrot, eggplant, apple, pear, bananas,
berries, grains, beans, nuts, seeds, rutabaga, plantain, taro,
okra, onion, parsnip, yam, sweet potato, yucca, papaya, mango,
pineapple, and the like. These foods include pureed, sliced, diced,
milled, grinded, powdered, or pulverized fruits, vegetables,
legumes, grains, nuts, beans, seeds and the like, including
products such as beans, rice, corn, wheat and the like. Singly or
in combinations, the aforementioned products and ingredients can be
manipulated to form sheets, slices or pieces of food composition
through extrusion or sheeting of a prepared dough or mixture and
the like. The dough or mixture thus formed then can be extruded or
cut into any desired shapes. There are many variations on this
basic procedure for manipulating flour or dough into a shape
suitable for the present process. For example, see U.S. Pat. Nos.
3,600,193 (mixing corn flour with seasonings); 3,922,370 (mixing
water, rice and rice flour); and 3,348,950 (mixing corn, sucrose,
water, and corn grits), each of which is hereby incorporated by
reference. Generally, the process of the invention can be used with
all foods that were heretofore fried or with foods that cannot
tolerate the frying process. The format of the food can include,
for example, sticks, strips, slices, chips, crinkle cut, waffles,
flakes, and the like. Flaked products may be made into bars or
cereals themselves or used as ingredients for granola, granola
bars, or add-ins to yogurt, cereals, trail mixes, snack mixes, and
the like.
[0055] For example, corn tortilla products or bean chips can be
prepared initially by forming a composition from water and corn or
bean flour, or alternatively cooked corn or beans, and cooked in
conventional tortilla ovens. Tortilla or bean strips or rounds can
be treated and processed using the current invention to produce fat
free or low fat snack products that have a crispy texture and
flavor of fried foods without frying in oil or oil substitutes.
Generally, the process of the present invention can be used with
all snack foods that have traditionally been fried in oil to
achieve a crisp texture and traditional fried flavor.
[0056] In another embodiment, the sheeted or extruded dough or
mixture described herein can be made from a potato mixture or other
starch material, alone or in combination with other ingredients,
and then processed in accordance with the teachings of the present
invention to a crispy finished product without frying.
[0057] Preferred food pieces are derived from fruits and/or
vegetables that have a generally solid inner matrix that is exposed
when sliced and demonstrates fracturability when a slice is bent.
In a preferred embodiment, the food pieces are derived from
potatoes such as those generally used to produce potato chips. In
preferred embodiments, the food pieces comprise a potato substrate.
The potato substrate may simply be farm-grown potatoes (e.g. raw
potatoes) of any variety. Such varieties include, but are not
limited to, Bintje, Russet Burbank, Yukon Gold, Kennebec, Norchip,
Atlantic, Shepody, Sebago, Red Pontiac, Red Warba, Irish Cobbler
"BC", Norgold Russet "BC". Nordand, Atlantic, White Rose, Superior,
Centennial Russet, Keswick "NB 1", Green Mountain, La Soda, Red La
Rouge, Red Nordland, Red Bliss, Yellow Finnish, Ruby Crescent, and
Australian Crescent, Russian Blue, Peruvian Blue, Superior,
Katahdin, and sweet potato varieties such as Beauregard, Jewel,
Nemagold, Centennial, Excel, Regal, Southern Delite (Hernandez,
Vardaman, Travis, White Delight, Sumor, Nancy Hall, Picadita,
Campeon, Star Leaf/Boniato, Japanese, Chinese, and Okinawan Purple
and the like.
[0058] In accordance with first and/or second embodiments of the
invention, a method is provided for making a snack food product,
comprising, [0059] (a) providing a plurality of cut or shaped food
pieces; [0060] (b) exposing the food pieces to a solution
comprising one or more enzymes and/or one or more cations to coat
the surface thereof; [0061] (c) thereafter blanching the plurality
of food pieces for a time sufficient to inactivate any enzymes on
the surface of the food pieces, wherein the food pieces have an
initial moisture level after the blanching step; and [0062] (d)
reducing the initial moisture level to a final moisture level of
from about 0.2 to about 10% by weight. In accordance with
additional embodiments, the final moisture level is preferably from
about 0.5 to about 5.0% by weight.
[0063] An intermediate moisture level of about 10 to about 80% by
weight, preferably about 10 to about 50% by weight, more preferably
about 15 to about 35% by weight may be achieved with a number of
the embodiments of the present invention. Thereafter, the food
pieces are exposed to a second moisture level reduction procedure
which reduces the intermediate moisture level to the final moisture
level. The intermediate and the final drying steps may further be
broken down to sub steps, or alternatively combined into one
step.
[0064] Suitable enzymes, forms taken by the enzymes, commercial
availability, etc. for use in accordance with the present invention
are chosen from one or more of the enzymes listed in U.S. Pat. No.
4,058,631; U.S. Pat. No. 5,312,631; and U.S. Pat. No. 7,056,544,
each of which is incorporated by reference herein. Preferably, the
enzyme is other than a high-temperature enzyme, such as the high
temperature amylase described in U.S. Pat. No. 5,441,758. However,
under certain circumstances, such an enzyme may be used in
accordance with the invention, and the use of a high temperature
enzyme is not disclaimed herein. Preferred enzymes in accordance
with the present invention include amylase, cellulase, invertase,
pectinase and amyloglucosidase, with amylase being the most
preferred. Preferably, the one or more enzymes is present in the
solution at a concentration of about 0.1 to about 5% by weight.
[0065] In accordance with the invention, the enzyme solution may
further comprise one or more cations, or the cations can be
provided in a solution without enzymes. The term "cation-producing
compound" is intended to include compounds in which cations are
produced in solution via dissociation of the cation with an anion,
either at ambient temperatures or with the addition of heat.
Suitable cation-producing compounds in accordance with the present
invention include, but are not limited to, alkali metal salts, such
as lithium, sodium and/or potassium salts; alkaline earth metal
salts, such as magnesium and/or calcium salts; aluminum compounds;
and group VA metal compounds, such as nitrogen, phosphorous and/or
bismuth compounds (e.g., ammonium). More preferred from this set of
compounds are calcium salts, magnesium salts, potassium salts,
aluminum compounds and nitrogen compounds, with calcium salts being
the most preferred. Preferably, the one or more cations is present
in the solution at a concentration of from about 0.1 to about 5% by
weight, more preferably from about 0.2 to about 2.5% by weight.
[0066] The exposure of the food pieces to the enzyme solution,
optionally including cations as described above, or the cation
solution without enzymes, provides various improved properties to
the snack food product. The term "improved property" is defined
herein as any property of a snack food product that is altered by
the action of the one or more enzymes and/or cations relative to a
snack food product in which the food pieces are not treated with
such a solution. The improved property may include, but is not
limited to, increased crispiness, reduced stickiness, increased
firmness of the raw and/or blanched material, reduced browning from
enzymatic and/or Maillard reactions, increased color brightening,
increased color retention, increased color enhancement, reduced
color fading, increased stiffness, increased rugged or smooth
appearance, improved flavor, and reduced fat content. Many of these
terms are defined more fully in U.S. Pat. No. 7,056,544, hereby
incorporated by reference. The other terms are defined in
accordance with their customary meaning as would be apparent to
those of ordinary skill in the art.
[0067] It will be appreciated that crispness and/or stiffness can
be increased in a measured way, so that, for instance, if a certain
crispness or a certain stiffness is desired to achieve certain
processing goals or for producing a certain finished snack food
product, crispness or stiffness can be controlled by varying the
amount of exposure to the one or more enzymes and/or cations.
[0068] The improved property may be determined by comparison of a
snack food product prepared in accordance with the methods of the
present invention, versus a snack food product prepared in
accordance with prior art methods. Techniques for determining such
improved properties achieved by use of the present methods are
described herein. Organoleptic qualities may be evaluated using
procedures well established in the food industry, and may include,
for example, the use of a trained panel of sensory evaluators.
Other methods could include texture analysis and comparisons such
as those disclosed herein below.
[0069] Preferably, the food pieces are exposed to the enzyme
solution (with or without cations), or the cation solution, for a
time of about 0.5 to about 45 minutes, more preferably about 0.5 to
about 15 minutes, most preferably about 0.5 to about 5 minutes.
[0070] In alternative embodiments, other nutrients including
vitamins and minerals, such as Vitamin A, Vitamin, B6, Vitamin B12,
Vitamin C, Vitamin D, Thiamin, Riboflavin, Niacin, Folic Acid,
Phosphorous, Magnesium, Copper, Calcium, Zinc, Iron and the like
can be added to the products of present invention either by
infusing such vitamins and minerals into the food pieces in the
enzyme treatment, cation treatment and/or blanching process, or in
an additional step or by spraying a compound including any desired
vitamins and/or minerals over the food pieces prior to or after
cooking. This procedure results in a product that is nutritionally
fortified and provides an opportunity to make snack food products
that are healthier. In alternate embodiments, flavor enhancers and
seasoning blends such as salt (NaCl), sugar, herb extracts, fruit
extracts, vegetable extracts and the like or a combination thereof
can be infused into the snack food product by steeping or soaking
the cut food pieces with the respective salt, sugar, herbs, fruits,
vegetables and the like, thereby incorporating these flavoring
components into the food pieces either in the blanch water and/or
by having a separate step following or prior to the blanching step
in which flavors are fused into the cut food pieces. Alternately,
cut food pieces may be soaked in concentrated flavor extracts that
are either aqueous or otherwise. In yet another embodiment, the
snack food products of the present invention may be coated with
chocolate, caramel, syrups, and coatings made from fruits or
vegetables or any other similar covering, thereby creating other
novel gourmet snacks that are free of, or alternatively low or high
in fat.
[0071] If preferred, any predetermined amount of digestible and/or
synthetic fat, such as an oil or oil substitute, may be added to
and/or blended and mixed with the dough or mixture prior to cooking
or alternatively can be applied in any process such as spraying on
the food pieces, prior to, during, or after the pre-cooking step.
Preferably, the oil is a cooking oil not containing fatty acids
such as canola, sunflower or safflower oils, which may be applied
to the vegetable pieces by either spraying the oil onto the food
pieces or by flash soaking the food pieces in oil or by any other
feasible method, such as applying to the blanch water or spraying
onto a conveyer belt or a tray before and/or after food pieces are
placed onto such tray or belt. In alternate embodiments where oil
is used, although any food grade oil or on substitute can be used,
the preferred oils will be unrefined oils and those having a low
smoke point, preferably extra virgin olive oil, hemp seed oil,
walnut oil, sesame oil, flaxseed oil, coconut oil, unrefined canola
oil, semi-refined canola oil, unrefined peanut oil, safflower oil,
sunflower oil, high-oleic sunflower oil, unrefined corn oil, soy
oil, unrefined soy oil, unrefined sesame oil, flavor Infused oils,
emulsified vegetable shortening, and the like, synthetic oils such
as OLESTRA.TM. and the like. Alternative oils that offer health
benefits, such as SMART BALANCE.TM., ENOVA.TM. and the like, may be
used either alone or in combination with other natural or synthetic
oils such as those discussed above.
[0072] Food Piece Preparation.
[0073] The food pieces are cut, formed or shaped from one or a
combination of food materials. For raw vegetables or raw plant
materials, the food pieces are preferably cleaned, optionally
peeled, and cut. Preferred vegetables such as potatoes, vegetables,
fruit, or other food products are preferably cut into slices,
sticks or strips of a desirable size and shape for chips, sticks,
shoestrings, wavy cut chips, crinkle cut chips, waffle cut chips,
straight cut chips and sticks and the like. After cutting, forming
or shaping, the prepared food pieces are preferably contacted with
an aqueous solution, such as a water, to remove free starch.
Removing the free starch is best for optimizing use and reducing
the amount of enzyme, plus free starch can leave a powdery
appearance after drying the chip.
[0074] Enzyme and/or Cation Treatment:
[0075] The prepared food pieces may be exposed to an enzyme
solution or a cation solution, more preferably an enzyme and cation
solution. When enzyme treatment is performed, the enzymes are
preferably used in amounts that contribute to one or more of the
improved properties as defined herein and/or provide at least one
of the following advantages: increasing the crispness, reducing the
stickiness and improving color of finished products. Without being
bound by theory, it is believed that the optional cations increase
the activity of the enzymes, reducing time in the solution, and
also make the cut food pieces more firm or rigid so they are easier
to process. Further, cations may also decrease enzymatic browning
as well as contribute to the snack food product's nutritional
profile.
[0076] The appropriate exposure to a given enzyme or cation for
improving a specific property or properties of a snack food product
will depend on the enzyme or cation in question. The skilled person
may determine a suitable enzyme or cation exposure on the basis of
methods known in the art. Where both enzyme and cation treatments
are performed, the treatments are preferably carried out
simultaneously using a single solution, although the treatments may
also be performed separately using an enzyme solution followed by a
cation solution, or a cation solution followed by an enzyme
solution. Salts and/or flavoring ingredients can also be added to
any of the solutions.
[0077] The enzymes to be used in the methods of the present
invention may be in any form suitable for the use in question,
e.g., in the form of a dry powder, agglomerated powder, or
granulate, in particular a non-dusting granulate, a liquid, in
particular a stabilized liquid, or a protected enzyme. Granulates
and agglomerated powders may be prepared by conventional methods,
e.g., by spraying the enzyme(s) onto a carrier in a fluid-bed
granulator. The carrier may consist of particulate cores having a
suitable particle size. The carrier may be soluble or insoluble,
e.g., a salt (such as NaCl or sodium sulfate), a sugar (such as
sucrose or lactose), a sugar alcohol (such as sorbitol), starch,
rice, corn grits, or soy. The enzymes may be contained in
slow-release formulations. Methods for preparing slow-release
formulations are well known in the art. Liquid enzyme preparations
may, for instance, be stabilized by adding nutritionally acceptable
stabilizers such as a sugar, a sugar alcohol or another polyol,
and/or lactic acid or another organic acid according to established
methods.
[0078] In preferred embodiments the enzyme and/or cation treatment
is applied prior to blanching. In alternative embodiments, the
enzyme and/or cation treatment is applied concurrently during the
blanching, or as an additional treatment after blanching. In the
case of certain shaped food pieces such as sheeted products that
are made from a combination of food materials or a dough, the
enzyme and/or cation treatment may be applied after the shaped food
pieces have been through the Initial baking step that is customary
in production of such products.
[0079] Blanching.
[0080] Several embodiments of the present invention include a step
whereby the food pieces are blanched. Preferably, the food pieces
are blanched for a time period sufficient to achieve any of the
following: 1) to inactivate any enzymes that naturally occur on the
surface of the pieces and/or to inactivate any enzymes added during
the enzyme treatment step described above; 2) to gelatinize at
least a portion of the naturally occurring starches; 3) to remove
excess free sugars so as to reduce Mallard browning and potential
for formation of acrylamides; and 4) to improve texture and flavor.
Typically, the food pieces are preferably blanched by immersion in
an aqueous solution, preferably containing from about 0.5% to about
8% by weight, more preferably from about 2% to about 5% by weight,
most preferably about 3% by weight of one or more cations, as
defined above. In preferred embodiments, the cations are selected
from NaCl, KCl, MgCl.sub.2 and CaCl.sub.2. The blanching may be
conducted at a temperature of preferably from about 60.degree. C.
to about 120.degree. C., more preferably from about 70.degree. C.
to about 100.degree. C. In alternate embodiments, the blanching may
be conducted by exposure to steam (at ambient or higher pressures),
preferably for about 15 seconds to about 10 minutes, more
preferably for about 40 seconds to about 3 minutes, depending upon
the amount of blanching desired. Alternatively, any known method of
blanching such as microwave, Ohmic heating, super heat steam,
Infrared heating and the like can be used in accordance with the
present invention.
[0081] If necessary, the food pieces are then preferably drained or
conveyed under an air curtain to remove excess water. In alternate
embodiments, any known method of removing excess surface water may
be employed. Salt can be added before, during or after blanching.
Any salts that are suitable for use in foods may be used, but NaCl,
KCl, MgCl.sub.2, CaCl.sub.2 and the like are preferred.
[0082] The blanching step may not be applicable and/or necessary in
cases of certain shaped food pieces such as sheeted products that
are made from a combination of food materials or a dough.
[0083] Reducing Moisture Level.
[0084] The moisture in the food pieces is preferably reduced to a
final moisture level of about 0.5 to about 10% by weight,
preferably about 0.5 to about 5% by weight. This moisture reduction
may be achieved in a number of different ways.
[0085] In one embodiment of the invention, the moisture reduction
step includes cooking the food pieces in one or more dryers or
ovens independently selected from the group consisting of forced
air convection ovens, fluidized bed dryers/ovens, vibrating
fluidized bed dryers/ovens, impingement dryers/ovens, pulsed
fluidized bed dryers/ovens (e.g., Aero Pulse dryers), rotary
dryers/ovens, rotary drum dryers/ovens, rotary spiral drum
dryers/ovens, tray ovens, stationary dryers/ovens, spiral
roasters/dryers (such as, for example, FMC Spiral Roto-Louvre
Roaster/Dryers), microwave dryers/ovens, infrared dryers/ovens,
super heat airless driers, vacuum driers, vacuum belt dryers and
ohmic dryers, or any similar drying/cooking apparatus.
[0086] In one embodiment, the food pieces are cooked for about 0.5
to about 40 minutes at temperature of from about 160.degree. F. to
about 400.degree. F., more preferably from about 275.degree. F. to
about 325.degree. F.
[0087] In another embodiment of the invention, the moisture
reduction comprises bringing the food pieces to a first temperature
for a first time period, and thereafter bringing the food pieces to
a second temperature for a second time period. Preferably, bringing
the food pieces to the first temperature for the first time period,
such as but not limited to a temperature of about 160.degree. F. to
about 400.degree. F., preferably between about 275.degree. F. to
about 375.degree. F. for a time of about 0.5 to about 40 minutes,
reduces the initial moisture level to an intermediate moisture
level of about 10 to about 80% by weight, and bringing the food
pieces to the second temperature for the second time period, such
as but not limited to a temperature of about 160.degree. F. to
about 375.degree. F., preferably between about 275.degree. F. and
about 350.degree. F., and more preferably between about 300.degree.
F. to about 325.degree. F. for a time of about 4 to about 35
minutes, preferably about 5 to about 12 minutes and more preferably
about 6 to about 11 minutes, reduces the Intermediate moisture
level to the final moisture level of about 0.5 to about 10%. In
preferred embodiments, the second temperature is lower than the
first temperature.
[0088] In other preferred embodiments, the first stage of the
process comprises drying the food pieces in a rotary dryer, rotary
drum dryer, rotary spiral drum dryer, fluidized bed dryer/oven or
vibrating fluidized bed dryer/oven to remove up to about 30% by
weight, preferably up to about 50% by weight, and most preferably
up to about 90% by weight of the initial moisture, and thereafter
the second stage reduces the moisture level to the final moisture
level of about 0.5 to about 10%. Preferably, the drying step is
conducted a temperature of about 160.degree. F. to about
400.degree. F., more preferably from about 275.degree. F. to about
350.degree. F., and even more preferably from about 300.degree. F.
to about 325.degree. F., for a time of about 2 to about 40 minutes,
more preferably from about 5 to about 25 minutes, and even more
preferably from about 6 minutes to about 18 minutes.
[0089] In still other preferred embodiments, the reduction of the
moisture level to the final moisture level of about 0.5 to about
10% may be accomplished solely using a rotary dryer, rotary drum
dryer, rotary spiral drum dryer, fluidized bed dryer/oven or
vibrating fluidized bed dryer/oven, in one or more drying steps. No
additional cooking procedure is utilized in this embodiment.
Generally the same temperature and time conditions indicated above
may be used in such an embodiment, over one or more stages.
[0090] Another embodiment of the present invention is
drying/cooking with the use of spiral roasters/dryers. The drying
principles and product behavior for this method closely mirror
rotary ovens and rotary drum drying, except the internal spiral
allows for precise control of drying time within the vessel.
Typically, in spiral roaster/dryers the drying air entry into the
product bed between the spiral flights is through the perforated
plate or screen wrapped around the flights. Precise control of
drying time within the vessel combined with the use of this method
will result in a higher product quality, process effectiveness and
added process efficiencies and output levels not experienced or
expected previously.
[0091] During any of the stages, the food pieces may be exposed to
air at an air speed of from about 200 to about 15,000 feet per
minute. According to additional, alternative embodiments of the
present invention, even lower air velocities may be used depending
on the food pieces being prepared and/or the equipment being used.
The process is further controlled by selectively increasing and/or
decreasing the air speed to control the exposure of the product to
temperature and airflow, thereby optimizing the quality of the
finished product. Sequential adjustments to temperature and airflow
allow for a controlled drying process that beneficially maintains
the product temperature below temperatures that cause browning and
carmelization until the product reaches a target moisture content.
Manipulation of the different zones of temperature and air velocity
allow for optimization of the texture, color, and flavor, as well
as economical efficiency of the process.
[0092] Other equipment, such as, for example, any similar type
rotary dryer or rotary drum dryer, "flash dryers", airless or
superheated steam dryer and the like such as, for example, those
available from Applied Chemical Technologies, Carrier Vibrating,
Inc., The Dupps Company and the like, may be used in place of the
dryers. Alternatively, microwave, infrared, impingement, vibrating
impingement, tray oven, convection oven, stationary oven, fluidized
bed or vibrating fluidized bed drying, vacuum drying, vacuum belt
drying or the like can be employed in the process of partially or
completely dehydrating the cut food pieces, each resulting in a
different degree of efficiency and level of output. The use of a
steam blancher, such as those available from the Lyco Company,
alone or in combination with any of the foregoing equipments,
provide numerous additional alternatives for either a partial or
complete dehydrating process. When applicable, any versions of the
foregoing equipment described herein in relation to the various
embodiments of the present invention, such as, for instances, batch
or continuous processing equipment, static or vibrating equipment
designs and the like may be employed.
[0093] Moisture sensing equipment such as those available from
Drying Technologies, Inc. (i.e., DTI 500, DTI 5000) and the like
can be Installed inside the rotary dryer or the like to ensure
proper drying conditions on an automated basis.
[0094] In preferred embodiments, the partially dried food pieces
are then transferred to an impingement oven, a fluidized bed
dryer/oven, a vibrating fluidized bed dryer/oven, a vacuum belt
dryer/oven or any other similar equipment via a conveyor belt or
any other conveying device or method. After moisture reduction, the
resultant snack food products may then be cooled either at ambient
or reduced temperatures, and optionally seasoned and/or coated as
desired and packaged for distribution and consumption.
[0095] Optional seasoning blends can be applied to products
preferably using adhesives such as gums, starches, proteins, that
can be used to create a sticky surface on the products for
adherence of the seasoning blends as is generally known within the
food industry.
[0096] To obtain a blistered effect on the product surface similar
to the typical appearance observed when foods are fried, the food
pieces are preferably cooked at a temperature or at least
265.degree. F. after about halfway through the moisture removal.
Next, the food pieces are cooked at a temperature of about
310.degree. F. with a high velocity air flow (e.g., an air speed of
about 500 to about 15,000 feet per minute) to achieve a final
moisture content of about 2 to about 5%. The final drying when
using certain types of equipment such as a vacuum dryer may take
place at temperatures below those indicated above.
[0097] The process efficiency can be further improved by, after the
moisture reduction is complete, running the food pieces through an
"Equilibrator" system, that takes the hot product, exhausts the air
from it, pulling off the heat thereby cooling it as the final
moisture is removed.
[0098] The invention also contemplates reducing the moisture level
down to the intermediate moisture level by any of the methods
described herein, cooling and storing the moist product at ambient,
refrigeration or freezer conditions, then subsequently frying,
drying or baking the product to achieve the final moisture level.
Alternatively, the frying step may immediately follow the steps of
reducing the moisture level down to the intermediate moisture
level.
[0099] In addition, the invention contemplates flash frying or
baking any of the snack food products prepared in accordance with
the invention, either in a commercial or retail setting or at
home.
[0100] The present invention also includes snack food products made
by any of the methods described herein.
[0101] Other aspects and advantages of the present invention will
be understood upon consideration of the following illustrative and
comparative examples.
Example 1
Potato Chips
[0102] Approximately 2.333 grams of Yukon Gold variety potatoes
were washed, then sliced to an average slice thickness of 1.90 mm,
yielding approximately 2288 grams of sliced potatoes. The sliced
potatoes were rinsed for 15 seconds in cold water (18.degree.
C./65.degree. F.) and drained. The drained potato slices were
placed in a solution of 0.5% amylase (American Labs, Inc. Fungal
Amylase-100,000 SKB/gram Lot ALI00517-04) and 1% aqueous Calcium
Chloride (32% aqueous solution Calcium Chloride from DSM Food
Specialties) and held for 3 minutes before draining. After
draining, the treated potato slices were blanched in 93.degree. C.
(200 degrees F.) water containing 3% salt (NaCl) (Cargill Top Flow
Salt) for 1 minute. Blanched potato slices were dipped into cold
water for about 15 seconds to halt cooking, then drained. The
potato slices were then placed directly on a conveyor belt of an
impingement oven (Impinger.RTM. I, Model No. 1240 from Lincoln Food
Service Products, Inc., Fort Wayne, Ind.) set at 140.degree.
C./285.degree. F. and belt time of 13.25 minutes. After drying, the
potato chips were allowed to cool completely, then placed in
moisture proof bags and sealed. The total yield was 467 grams of
potato chips. The resulting chips were observed visually and
determined to have a light golden color, a good potato chip flavor
and a crisp light texture.
[0103] Samples were analyzed for moisture using the convection oven
method; by measuring the weight lost as a result of heating a
ground sample (4 grams, run in triplicate) in a convection oven
under controlled conditions (100.degree. C. for 24 hours). The
percent of weight lost was reported as the percent of moisture in
the sample. In this example, the final moisture content was
4.42%.
[0104] Samples were analyzed for fat using the chloroform
extraction method of F. I. Shahil (see reference provided below)
with minor variations:
[0105] Prior to extraction, the sample is ground in a blender.
1. Prepare a 2:1 solution of chloroform:methanol. 2. Measure 10 g
of ground sample Into a flask; add 50 mls of 2:1
chloroform/methanol solution. 3. Stir covered for 1 hour. 4. Pour
into a clean flask through filter paper. 5. Rinse the initial flask
and remaining solids into the new flask with a small amount of the
2:1 solution of chloroform:methanol. 6. Add 30-35 mls of distilled
water and mix. 7. Let sit at 4.degree. C. overnight. 8. Remove
settled top layer containing water and methanol with a water
aspirator and glass pipette. 9. Weigh a new round bottom flask and
record. 10. Pour the remaining solution into the new flask through
a filter, pass the remaining layer of chloroform (and fat) over
sodium sulfate to remove any remaining water. Wash all of the fat
into the flask using additional chloroform. 11. Using a rotovap at
50.degree. C./80 rpm, remove (by evaporation) the remaining
chloroform. 12. Place flask in the chemical fume hood overnight to
completely evaporate any remaining chloroform. 13. Weigh flask
after drying is complete, record and determine the amount of
fat.
[0106] The results indicated that the samples contained an average
of about 0.30% fat. The average final thickness of the sample chips
after drying was determined to be 1.38 mm by measuring thickness of
10 chips using digital calipers.
[0107] The "chloroform method" is based upon the method disclosed
by F. I. Shahi, "Extraction and Measurement of Total Lipids".
Current Protocols in Food Analytical Chemistry, John Wiley and
Sons, 2003, pp D1.1.4.
[0108] The "moisture method" is based upon the method disclosed by
R. P. Ruls, "Gravlmetric Determination of Water by Drying and
Weighing: Measuring Moisture using a Convection Oven", Current
Protocols in Food Analytical Chemistry. John Wiley and Sons, 2003,
pp A1.1.1.
[0109] The texture of the potato chips was evaluated using a TA.XT2
Texture Analyzer using a 0.25'' diameter ball probe and a
chip/cracker fixture. Individual chips were rested over the 18 mm
diameter opening on the plate's cylindrical opening, and were
punctured with the ball probe. The ball probe traveled at 4.0 mm/s
until a force of 10 grams was detected; then the ball probe was
punctured through the chips at a speed of 1.0 mm/second. The probe
was withdrawn at 10.0 mm/second. A sampling of 25 chips was used
for each test. Analysis of the test chips resulted in an average
peak force of 379 grams, which is statistically similar to
LAY'S.RTM. Light Chips (OLESTRA.TM.) 825.59 grams of force and Low
Fat KETTLE KRISPS.TM. at 416.06 grams of force. LAY'S Classic was
slightly less at 254.23 grams of force.
[0110] Test 1: Comparison of Chip Attributes: Samples of Potato
Chips of the Present Invention prepared by the process described in
Example 1 compared with popular chips currently in the market.
TABLE-US-00001 TABLE 1 Comparison of Chip Attributes. Texture
Average Analysis Ratio of % Fat Percent Percent Thickness Grams of
Moisture to Sample g./oz. Fat Moisture (mm) force % Fat Test
Product 0.084 0.30%* 4.42% 1.38 379.87 14.73 LAYS .RTM. 10**
35.71%** 3.80% 1.44 254.23 0.11 Classic LAYS .RTM. Light 0** 0%**
3.45% 1.40 325.59 0 (Contains Olestra .TM.) Lightly Salted 8**
28.57%** 4.26% 1.30 583.87 0.15 Kettle Chips Low Fat Kettle 1.5**
5.36% 4.99% 1.55 416.09 0.93 Krisps Terra Yukon 6** 21.42%** 6.27%
2.15 1090.40 0.29 Gold .TM. *Fat analysis by Chloroform Extraction
Method **Information from Nutritional Label
[0111] Test 2: Density measurement of potato chips using the
multipycnometer. The multipycnometer (Quantachrome model
MVP-D160-E) employs the technique of fluid displacement to
determine volume. The fluid used in the instrument is helium.
Potato chip volume was determined by measuring the pressure
difference when a known quantity of helium is allowed to flow from
a known reference volume into the sample cell containing the chips.
Samples were weighed before measuring the volume. Each chip was
broken into 2-4 pieces to allow them to fit into the measuring
cell. Densities were calculated using the formula:
W V C - { V R * [ ( P 1 / P 2 ) - 1 ] } ##EQU00001##
W=weight of potato chips (g) V.sub.C=Cell volume (cm.sup.3)*
V.sub.R=Reference volume (cm.sup.3)* P.sub.1=pressure reading of
the reference P.sub.2=pressure reading of the cell *V.sub.C and
V.sub.R were established during instrument calibration.
TABLE-US-00002 TABLE 2 Pycnometer Density Calculations of Potato
Chips. Density Average Sample Replicates g/(cm.sup.3) g/(cm.sup.3)
Test Product 1 1.345 1.351 (regular) 2 1.359 3 1.350 Test Product 1
1.281 1.291 (wavy) 2 1.315 3 1.278 LAY'S .RTM. Classic 1 1.178
1.191 2 1.197 3 1.197 Low Fat Kettle 1 1.373 1.355 Krisps 2 1.327 3
1.365 Ruffles .RTM. 1 1.156 1.171 2 1.181 3 1.175
Example 2
Regular Fat-Free Potato Sticks
[0112] Russet Burbank Potatoes were peeled and cut Julienne style
lengthwise to achieve approximately 2 mm height and width. After
slicing 540 grams of these, the raw potato sticks were rinsed for
under 65.degree. F. running water for 15 seconds. Then the rinsed
sticks were held in a solution containing 500 grams water
(43.degree. C./110.degree. F.), 5 grams bacterial amylase (Lot No.
ALI05175-04. American Laboratories, Inc.), 5 grams calcium chloride
solution (32% solution Calcium Chloride from DSM Food Specialties)
for 3 minutes. The enzyme treated potato sticks were drained, then
blanched in 87.degree. C./190.degree. F. water containing 3%
Cargill Sea Salt (3000 g cold water, plus 90 g salt) for 1 minute
30 seconds before draining. Blanched potato sticks were placed
directly on perforated aluminum tray and put into an impingement
oven (Impinger.RTM. I, Model No. 1240 from Lincoln Food Service
Products, Inc. Fort Wayne, Ind.) set at 140.degree. C./285.degree.
F. Oven belt speed was set at 24 minutes. Every 5 minutes, the tray
was shaken to stir the potato sticks to allow for even drying. The
process yielded approximately 103 grams of fat-free potato sticks,
which were then cooled and packaged. The potato sticks were
evaluated by trained sensory professionals and were noted to have a
pleasant cooked potato flavor, golden color, and light crisp
texture.
Example 3
Larger Size, Puffed Potato Strips
[0113] Yukon Gold potatoes were peeled and cut slices approximately
2 mm thick. These slices were then cut into strips approximately 6
mm wide. Approximately 750 grams of these raw potato strips were
rinsed under 65.degree. F. running water for 15 seconds. Then the
rinsed strips were held in a solution containing 500 grams water
(43.degree. C./110.degree. F.), 5 grams bacterial amylase (Lot No.
ALI05175-04, American Laboratories, Inc.), 5 grams calcium chloride
(32% solution Calcium Chloride from DSM Food Specialties) for 3
minutes. The enzyme treated potato strips were drained, then
blanched in 87.degree. C./190.degree. F. water containing 3%
Cargill Sea Salt (3000 g water, plus 90 g salt) for 1 minute 30
seconds before draining. The blanched potato strips were placed
directly on perforated aluminum tray and put into an impingement
oven (Impinger.RTM. I, Model No. 1240 from Lincoln Food Service
Products, Inc., Fort Wayne, Ind.) set at 135.degree. C./275.degree.
F. Oven belt speed was set at 27 minutes. Every 5 minutes, the tray
was shaken to stir the potato strips to allow for even drying. The
process yielded approximately 129 grams of fat-free potato strips,
with a right texture, approximately 90% of the strips puffed into
almost cylindrical shape, giving them the appearance of crispy
French fries. The fat-free potato strips were judged by trained
sensory professionals to have a very rich buttery flavor, crisp
light texture and appetizing appearance.
Example 4
Carrot Chips
[0114] Carrots were peeled and cut into slices approximately 2 mm
thick. Approximately 500 grams of these carrot slices were rinsed
under 65.degree. F. running water for 15 seconds. Then the rinsed
carrot slices were held in a solution containing 500 grams water
(43.degree. C./110.degree. F.), 5 grams bacterial amylase (Lot No.
ALI05175-04, American Laboratories, Inc.), 5 grams calcium chloride
(32% solution Calcium Chloride from DSM Food Specialties) for 3
minutes. The enzyme treated carrot slices were drained, then
blanched in 87.degree. C./190.degree. F. water containing 2%
Cargill Sea Salt 2000 g water, plus 40 g. salt) for 1 minute 15
seconds before draining. The blanched carrot slices were placed
directly on belt of an impingement oven (Impinger.RTM. I, Model No.
1240 from Lincoln Food Service Products, Inc., Fort Wayne, Ind.)
set at 135.degree. C./275.degree. F. Oven belt speed was set at 15
minutes. The process yielded approximately 120 grams of fat-free
carrot chips, with a light texture, bright orange color and
pleasant sweet carrot flavor.
Example 5
Fat-Free Beet Chips
[0115] Fresh red beets were peeled and cut into slices
approximately 1.6 mm thick. Approximately 590 grams of these beet
slices were rinsed under 65.degree. F. running water for 15
seconds. Then the rinsed beet slices were held in a solution
containing 500 grams water (43.degree. C./110.degree. F.), 5 grams
bacterial amylase (Lot No. ALI05175-04, American Laboratories,
Inc.), 5 grams calcium chloride (32% solution Calcium Chloride from
DSM Food Specialties) for 3 minutes. The enzyme treated beet slices
were drained, then blanched in 87.degree. C./190.degree. F. water
containing 2% Cargill Sea Salt (2000 g water, plus 40 g salt) for 1
minute 15 seconds before draining. The blanched beet slices were
placed directly on belt of an impingement oven (Impinger.RTM. I,
Model No. 1240 from Lincoln Food Service Products, Inc., Fort
Wayne, Ind.) set at 135.degree. C./275.degree. F. Oven belt speed
was set at 15 minutes. The process yielded approximately 130 grams
of fat-free beet chips, with a light, crisp texture, dark beet red
color and pleasant beet flavor.
Example 6
Fat-Free Parsnip Chips
[0116] Fresh parsnip roots were peeled and cut into slices
approximately 1.6 mm thick. Approximately 500 grams of these
parsnip slices were rinsed under 65.degree. F. running water for 15
seconds. Then the rinsed parsnip slices were held in a solution
containing 500 grams water (43.degree. C./110.degree. F.), 5 grams
bacterial amylase (Lot No. ALI05175-04, American Laboratories,
Inc.), 5 grams calcium chloride (32% solution Calcium Chloride from
DSM Food Specialties) for 3 minutes. The enzyme treated parsnip
slices were drained, then blanched in 87.degree. C./190.degree. F.
water containing 2% Cargill Sea Salt (2000 g water, plus 40 g salt)
for 1 minute 15 seconds before draining. Blanched parsnip slices
were placed directly on belt of an impingement oven (Impinger.RTM.
I, Model No. 1240 from Lincoln Food Service Products, Inc., Fort
Wayne, Ind.) set at 135.degree. C./275.degree. F. Oven belt speed
was set at 13 minutes. The process yielded approximately 120 grams
of fat-free parsnip chips, with a light, crisp texture, creamy tan
color and pleasant parsnip flavor.
Example 7
Fat-Free Yucca Root (Maniac or Cassava) Chips
[0117] Fresh yucca roots were peeled and cut into slices
approximately 1.6 mm thick. Approximately 1000 grams of these yucca
root slices were rinsed under 65.degree. F. running water for 15
seconds. Then the rinsed yucca root slices were held in a solution
containing 750 grams water (43.degree. C./110.degree. F.), 7.5
grams bacterial amylase (Lot No. ALI05175-04, American
Laboratories, Inc.), 7.5 grams calcium chloride (32% solution
Calcium Chloride from DSM Food Specialties) for 3 minutes. The
enzyme treated yucca root slices were drained, then blanched in
87.degree. C./190.degree. F. water containing 2% Cargill Sea Salt
(2000 g water, plus 40 g salt) for 1 minute 15 seconds before
draining. Blanched yucca root slices were placed in apple juice for
2 minutes, then drained and placed directly on belt of an
impingement oven (Impinger.RTM. I, Model No. 1240 from Lincoln Food
Service Products, Inc., Fort Wayne, Ind.) set at 135.degree.
C./275.degree. F. Oven belt speed was set at 14 minutes. The
process yielded approximately 200 grams of fat-free yucca root
chips, with a light, crisp texture, very white in color and
pleasant slightly sweet flavor.
Example 8
Fat-Free Pineapple Chips
[0118] Fresh pineapple were cored, the cored portion was then cut
into slices approximately 1.6 mm thick. Approximately 500 grams of
these pineapple core slices were rinsed under 659: running water
for 15 seconds. Then the rinsed pineapple core slices were held in
a solution containing 500 grams water (43.degree. C./110.degree.
F.), 5 grams bacterial amylase (Lot No. ALI05175-04, American
Laboratories, Inc.), 5 grams calcium chloride (32% solution Calcium
Chloride from DSM Food Specialties) for 3 minutes. The enzyme
treated pineapple slices were drained, then blanched in 87.degree.
C./190.degree. F. water containing 2% Cargill Sea Salt (2000 g
water, plus 40 g salt) for 1 minute 15 seconds before draining. The
blanched pineapple slices were placed directly on belt of an
impingement oven (Impinger.RTM. I, Model No. 1240 from Lincoln Food
Service Products, Inc., Fort Wayne, Ind.) set at 140.degree.
C./285.degree. F. Oven belt speed was set at 22 minutes. The
process yielded approximately 128 grams of fat-free pineapple
chips, with a light, crisp texture, bright yellow color and
pleasant cooked pineapple flavor
Example 9
Fat-Free Apple Chips
[0119] Fresh Fuji apples were washed then cut into slices
approximately 2.0 mm thick. Approximately 900 grams of these apple
slices were rinsed under 65.degree. F. running water for 15
seconds, then placed in a 1% citric acid solution to prevent
enzymatic browning. Then apple slices were held in a solution
containing 500 grams water (43.degree. C./110.degree. F.), 5 grams
bacterial amylase (Lot No. ALI05175-04, American Laboratories,
Inc.), 5 grams calcium chloride (32% solution Calcium Chloride from
DSM Food Specialties) for 3 minutes. The enzyme treated apple
slices were drained, then blanched in 87.degree. C./190.degree. F.
water containing 2% Cargill Sea Salt, 2% calcium chloride solution
(2000 g water, plus 40 g salt and 40 g calcium chloride solution)
for 1 minute 15 seconds before draining. The blanched apple slices
were placed directly on belt of an impingement oven (Impinger.RTM.
I, Model No. 1240 from Lincoln Food Service Products, Inc., Fort
Wayne, Ind.) set at 140.degree. C./285.degree. F. Oven belt speed
was set at 14 minutes. The process yielded approximately 220 grams
of fat-free apple chips, with a light, crisp texture, light tan
color and pleasant cooked apple flavor.
Example 10
Fat-Free Pear Chips
[0120] Fresh d'Anjou pears were washed then cut into slices
approximately 2.0 mm thick. Approximately 850 grams of these pear
slices were rinsed under 65.degree. F. running water for 15
seconds, then placed in a 1% citric acid solution to prevent
enzymatic browning. Then pear slices were held in a solution
containing 500 grams water (43.degree. C./110.degree. F.), 5 grams
bacterial amylase (Lot No. ALI05175-04. American Laboratories,
Inc.), 5 grams calcium chloride (32% solution Calcium Chloride from
DSM Food Specialties) for 3 minutes. The enzyme treated pear slices
were drained, then blanched in 87.degree. C./190.degree. F. water
containing 2% Cargill Sea Salt, 2% calcium chloride solution (2000
g water, plus 40 g salt and 40 g calcium chloride solution) for 1
minute 15 seconds before draining, The blanched pear slices were
placed directly on belt of an impingement oven (Impinger.RTM. I,
Model No. 1240 from Lincoln Food Service Products, Inc., Fort
Wayne, Ind.) set at 140.degree. C./285.degree. F. Oven belt speed
was set at 15 minutes. The process yielded approximately 200 grams
of fat-free pear chips, with a light, crisp texture, light tan
color and pleasant cooked pear flavor.
Example 11
Fat-Free Purple Sweet Potato Chips
[0121] Purple Sweet Potatoes were peeled and sliced into slices
approximately 1.8 mm thick. After slicing, 1000 grams of these raw
sweet potato slices were rinsed under 65.degree. F. running water
for 15 seconds. Then the rinsed slices were blanched in 87.degree.
C./190.degree. F. water containing 2% Cargill Sea Salt (2000 g cold
water, plus 40 g salt) for 1 minute 30 seconds before draining.
Blanched potato slices were placed directly on chain belt of
impingement oven (Impinger.RTM. I, Model No. 1240 from Lincoln Food
Service Products, Inc., Fort Wayne, Ind.) set at 140.degree.
C./285.degree. F. Oven belt speed was set at 14 minutes. The
process yielded approximately 225 grams of fat-free sweet potato
chips, which were cooled and packaged. The purple sweet potato
slices were evaluated by trained sensory professionals and were
noted to have a very pleasant sweet flavor, novel dark purple
color, and light crisp texture.
Example 12
Fat-Free Radish Chips
[0122] Fresh red table radishes were cut into slices approximately
1.75 mm thick. Approximately 500 grams of these radish slices were
rinsed under 65.degree. F. running water for 15 seconds. Then the
rinsed radish slices were held in a solution containing 500 grams
water (43.degree. C./110.degree. F.), 5 grams bacterial amylase
(Lot No. ALI05175-04, American Laboratories, Inc.), 5 grams calcium
chloride (32% solution Calcium Chloride from DSM Food Specialties)
for 3 minutes. The enzyme treated radish slices were drained, then
blanched in 87.degree. C./190.degree. F. water containing 2%
Cargill Sea Salt (2000 g water, plus 40 g salt) for 45 seconds
before draining. Blanched radish slices were placed directly on
belt of an impingement oven (Impinger.RTM. I, Model No. 1240 from
Lincoln Food Service Products, Inc., Fort Wayne. IN) set at
135.degree. C./275.degree. F. Oven belt speed was set at 11.5
minutes. The process yielded approximately 109 grams of fat-free
radish chips, with a light, crisp texture, creamy tan color and
astringent radish flavor.
Example 13
Fat-Free Taro Chips
[0123] Fresh taro roots were peeled and cut into slices
approximately 1.6 mm thick. Approximately 1000 grams of these taro
slices were rinsed under 65.degree. F. running water for 15
seconds. Then the rinsed taro slices were held in a solution
containing 750 grams water (43.degree. C./110.degree. F.), 7.5
grams bacterial amylase (Lot No. ALI05175-04, American
Laboratories, Inc.), 5 grams calcium chloride (32% solution Calcium
Chloride from DSM Food Specialties) for 3 minutes. The enzyme
treated taro slices were drained, then blanched in 87.degree.
C./190.degree. F. water containing 2% Cargill Sea Salt (2000 g
water, plus 40 g salt) for 1 minute before draining. Blanched taro
slices were placed directly on belt of an impingement oven
(Impinger.RTM. I, Model No. 1240 from Lincoln Food Service
Products, Inc., Fort Wayne, Ind.) set at 135.degree. C./275.degree.
F. Oven belt speed was set at 12 minutes. The process yielded
approximately 255 grams of fat-free taro chips, with a light, crisp
texture, creamy tan color retaining the natural pink/red specks
inherent in the taro root. Flavor was very mild, slightly sweet,
and pleasant.
Example 14
Fat-Free Pumpkin Chips
[0124] A small fresh pumpkin (approximately 10 inches in diameter)
was cut in quarters, seeds were removed, then the flesh was cut
into slices approximately 1.8 mm thick. Approximately 1000 grams of
these raw pumpkin slices were rinsed under 65.degree. F. running
water for 15 seconds. Then the rinsed pumpkin slices were held in a
solution containing 750 grams water (43.degree. C./110.degree. F.),
7.5 grams bacterial amylase (Lot No. ALI05175-04, American
Laboratories, Inc.), 5 grams calcium chloride (32% solution Calcium
Chloride from DSM Food Specialties) for 3 minutes. The enzyme
treated pumpkin slices were drained, then blanched in 87.degree.
C./190.degree. F. water containing 2% Cargill Sea Salt (2000 g
water, plus 40 g salt) for 30 seconds before draining. The blanched
pumpkin slices were placed directly on belt of an impingement oven
(Impinger.RTM. I, Model No. 1240 from Lincoln Food Service
Products, Inc., Fort Wayne, Ind.) set at 135.degree. C./275.degree.
F. Oven belt speed was set at 11 minutes. The process yielded
approximately 246 grams of fat-free pumpkin chips, with a light,
crisp texture, orange/tan color and a very mild and pleasant
flavor.
Example 15
Fat-Free Rutabaga Chips
[0125] Fresh rutabagas peeled and were cut into slices
approximately 1.6 mm thick. Approximately 500 grams of these
rutabaga slices were rinsed under 65.degree. F. running water for
15 seconds. Then the rinsed rutabaga slices were held in a solution
containing 500 grams water (43.degree. C./110.degree. F.), 5 grams
bacterial amylase (Lot No. ALI05175-04, American Laboratories,
Inc., Omaha, Nebr.), 5 grams calcium chloride (32% solution Calcium
Chloride from DSM Food Specialties) for 3 minutes. The enzyme
treated rutabaga slices were drained, then blanched in 87.degree.
C./190.degree. F. water containing 2% Cargill Sea Salt (2000 g
water, plus 40 g salt) for 1 minute 10 seconds before draining. The
blanched rutabaga slices were placed directly on belt of an
impingement oven (Impinger.RTM. I, Model No. 1240 from Lincoln Food
Service Products, Inc., Fort Wayne, Ind.) set at 135.degree.
C./275.degree. F. Oven belt speed was set at 12.5 minutes. The
process yielded approximately 134 grams of fat-free rutabaga chips,
with a light, crisp texture, bright tan color and typical cooked
rutabaga flavor.
Example 16
Fat Free Zucchini Chips
[0126] Several small fresh zucchini (approximately 2.5 inches in
diameter and 8 inches in length were peeled, the center core
(approximately 0.5 inch diameter) was removed, then the prepared
zucchini were cut into slices approximately 2.0 mm thick using a
kitchen mandolin with a serrated blade. Approximately 1000 grams of
these raw zucchini slices were rinsed under 65.degree. F. running
water for 15 seconds. Then the rinsed slices were held in a
solution containing 750 grams water (43.degree. C./110.degree. F.),
15 grams dried enzyme preparation (Lot No. SI9700, Multlzyme II,
Enzyme Development Corp. New York, N.Y.), 10 grams calcium chloride
(32% solution Calcium Chloride from DSM Food Specialties) for 3
minutes. The enzyme treated zucchini slices were drained, then
blanched in 87.degree. C./190.degree. F. water containing 2%
Cargill Sea Salt (2000 g water, plus 40 g salt) for 45 seconds
before draining. The blanched zucchini slices were placed directly
on belt of an impingement oven (Impinger.RTM. I, Model No. 1240
from Lincoln Food Service Products, Inc., Fort Wayne, Ind.) set at
135.degree. C./275.degree. F. Oven belt speed was set at 18
minutes. The process yielded approximately 96 grams of fat-free
zucchini chips, with a light, crisp texture, light yellow/tan color
with a very mild and pleasant flavor.
Example 17
Fat-Free Mushrooms Chips
[0127] Several small fresh button mushrooms (approximately 2.5-3
inches cap diameter) were cut into slices approximately 2.4 mm
thick using a kitchen mandolin. Approximately 500 grams of these
raw mushroom slices were rinsed under 65.degree. F. running water
for 15 seconds. Then the rinsed slices were held in a solution
containing 750 grams water (43.degree. C./110.degree. F.), 15 grams
dried enzyme preparation (Lot No. S19700, Multizyme II. Enzyme
Development Corp. New York, N.Y.), 10 grams calcium chloride (32%
solution Calcium Chloride from DSM Food Specialties) for 3 minutes.
The enzyme treated mushroom slices were drained, then blanched in
87.degree. C./190.degree. F. water containing 2% Cargill Sea Salt
(2000 g water, plus 40 g salt) for 45 seconds before draining.
Blanched mushroom slices were placed a screen sheet and placed in
an impingement oven (Impinger.RTM. I, Model No. 1240 from Lincoln
Food Service Products, Inc., Fort Wayne, Ind.) set at 135.degree.
C./275.degree. F. Oven belt speed was set at 22 minutes. The
process yielded approximately 64 grams of fat-free mushroom chips,
with a very light texture, tan color very mild and pleasant pungent
cooked mushroom flavor.
Example 18
Fat-Free Bean Sticks
[0128] Fresh green beans (Blue Lake Variety) were rinsed, the ends
were trimmed, then approximately 1000 grams of these raw green
beans were rinsed under 65.degree. F. running water for 15 seconds.
Next the rinsed bean pods were held in a solution containing 750
grams water (43.degree. C./110.degree. F.), 15 grams dried enzyme
preparation (Lot No. SI9700, Multizyme II, Enzyme Development Corp.
New York, N.Y.), 10 grams calcium chloride (32% solution Calcium
Chloride from DSM Food Specialties) for 3 minutes. The enzyme
treated bean pods were drained, then blanched in 87.degree.
C./190.degree. F. water containing 2% Cargill Sea Salt (2000 g
water, plus 40 g salt) for 4 minutes before draining. The blanched
green bean pods were placed a screen sheet on belt of an
impingement oven (Impinger.RTM. I, Model No. 1240 from Lincoln Food
Service Products, Inc., Fort Wayne, Ind.) set at 135.degree.
C./275.degree. F. Oven belt speed was set at 28 minutes. The
process yielded approximately 172 grams of fat-free green bean
snack sticks, with a light, crisp texture, green and brown in color
with a very mild and pleasant flavor.
Example 19
Regular Fat Free Potato Chips, Pre-Processed Slices Held Under
Refrigerated Conditions for 1 Week, then Dried/Cooked
[0129] Atlantic Variety chipping potatoes were peeled and sliced
using a Dito Dean vegetable slicer with a C2 blade, to achieve a
slice thickness of approximately 1.60 mm. After slicing, 1000 grams
of these raw potato slices were rinsed for under 65.degree. F.
running water for 15 seconds. Then the rinsed slices were held in a
solution containing 1000 grams water (43.degree. C./110.degree.
F.), 10 grams bacterial amylase (Lot No. ALI05175-04, American
Laboratories, Inc.) and 10 grams calcium chloride solution (32%
solution Calcium Chloride from DSM Food Specialties) for 3 minutes.
The enzyme treated potato slices were drained, then blanched in
87.degree. C./190.degree. F. water containing 2% Cargill Sea Salt
(3000 g cold water, plus 60 g. salt) for 1 minute before draining.
The blanched potato slices were cooled in ice water, then drained
and stored in plastic bags in a cooler at 3.degree. C./38.degree.
F. for 7 days. Samples were removed from the cooler, placed In on a
metal screen in a single layer and processed in an industrial Air
Force.RTM. impingement oven (Heat and Control Company, Hayward,
Calif. 94545) set at 176.degree. C./350.degree. F. for 3.5 minutes.
The partially dried potato slices were then piled together to
create a bed depth of 1 inch, then processed through a second Air
Force.RTM. impingement oven (Heat and Control Company, Hayward,
Calif. 94545) for an additional 3.5 minutes at 148.degree.
C./300.degree. F. The process yielded approximately 200 grams of
fat-free potato chips, which were cooled and packaged. The potato
chips were evaluated by trained sensory professionals and were
noted to have a pleasant cooked potato flavor, golden color, and
light crisp texture. The seven day holding time for the
pre-processed slices did not affect the texture or flavor of the
finished product.
Example 20
Novel Sweet Potato Cereal-Regular Sweet Potato Flakes
[0130] Novel Sweet Potato Cereal-Regular Sweet Potatoes were peeled
and cut lengthwise into strips approximately 0.75-1 inch thick,
then the strips were sliced across into small flakes approximately
2 mm thick. After slicing, approximately 1000 grams of these raw
sweet potato flakes were rinsed under 65.degree. F. running water
for 15 seconds. Then the rinsed flakes were blanched in 87.degree.
C./190.degree. F. water containing 1% Cargill Sea Salt and 0.5%
calcium chloride solution (32% solution Calcium Chloride from DSM
Food Specialties) (5000 g cold water, plus 50 g. salt, 25 grams
calcium chloride) for 1 minute before draining. The blanched sweet
potato flakes were placed directly on an aluminum screen, and put
into an impingement oven (Impinger.RTM. I. Model No. 1240 from
Lincoln Food Service Products, Inc., Fort Wayne, Ind.) set at
140.degree. C./285.degree. F. Oven belt speed was set at 17
minutes. Every 5 minutes, the screen was shaken to stir the potato
flakes to allow for even drying. The process yielded approximately
284 grams of fat-free sweet potato flakes, which were cooled and
packaged. The sweet potato flakes were evaluated by trained sensory
professionals and were noted to have a pleasant sweet nutty flavor,
golden brown color, and light crisp texture when eaten with milk in
a bowl like a grain based cereal. The product retained its crisp
texture for a bowl life of 7-8 minutes.
Example 21
Regular Fat-Free Potato Chips Made by Initial Dry with Infrared
Heater, then Finish Dry in Impingement
[0131] Atlantic Variety chipping potatoes were peeled and sliced
using a Dito Dean vegetable slicer with a C2 blade, to achieve a
slice thickness of approximately 1.60 mm. After slicing, 1000 grams
of the raw potato slices were rinsed for under 65.degree. F.
running water for 15 seconds. Then the rinsed slices were held in a
solution containing 1000 grams water (43.degree. C./110.degree.
F.), 10 grams bacterial amylase (Lot No. ALI05175-04, American
Laboratories, Inc.) and 10 grams calcium chloride solution (32%
solution Calcium Chloride from DSM Food Specialties) for 3 minutes.
The enzyme treated potato slices were drained, then blanched in
87.degree. C./190.degree. F. water containing 2% Cargill Sea Salt
(3000 g cola water, plus 60 g. salt) for 1 minute before draining.
The blanched potato slices were placed on a conveyor and run under
an infra red heater unit for 30 seconds. Then the partially dried
slices were immediately put into an industrial Air Force.RTM.
impingement oven (Heat and Control Company, Hayward, Calif. 94545)
set at 176.degree. C./350.degree. F. for 3 minutes. The partially
dried potato slices were then piled together to create a bed depth
of I inch, then processed through a second Air Force.RTM.
impingement oven (Heat and Control Company, Hayward, Calif. 94545)
for an additional 3 minutes at 148.degree. C./300.degree. F. The
process yielded approximately 200 grams of fat free potato chips,
which were cooled and packaged. The potato chips were evaluated by
trained sensory professionals and were noted to have a pleasant
cooked potato flavor, golden color, and light crisp texture.
Example 22
Regular Fat-Free Potato Chips Made by Initial Dry in Microwave,
then Finish Dry in Impingement Oven
[0132] Atlantic Variety chipping potatoes were peeled and sliced
using a Dito Dean vegetable slicer with a C2 blade, to achieve a
slice thickness of approximately 1.60 mm. After slicing, 1000 grams
of the raw potato slices were rinsed for under 65.degree. F.
running water for 15 seconds. Then the rinsed slices were held in a
solution containing 1000 grams water (43.degree. C./110.degree.
F.), 10 grams bacterial amylase (Lot No. ALI05175-04, American
Laboratories. Inc.) and 10 grams calcium chloride solution (32%
solution Calcium Chloride from DSM Food Specialties) for 3 minutes.
Enzyme treated potato slices were drained, then blanched in
87.degree. C./190.degree. F. water containing 2% Cargill Sea Salt
(3000 g cold water, plus 60 g. salt) for 1 minute before draining.
The blanched potato slices were placed in on plastic disc and put
into a Microwave Oven (Amana RadarRange, Model No. RS415T, 1500
Watts, manufactured by Amana Appliances, Amana, Iowa) for 1 minute
at full power. After microwave drying the partially dried potato
slices were then placed directly on the belt in an industrial Air
Force.RTM. impingement oven (Heat and Control Company, Hayward,
Calif. 94545) set at 176.degree. C./350.degree. F. for 1.5 minutes.
The potato slices were then piled together to create a bed depth of
1 inch, then ran through a second Air Force.RTM. impingement oven
(Heat and Control Company, Hayward, Calif. 94545) for an additional
1.5 minutes but at 148.degree. C./300.degree. F. The process
yielded approximately 200 grams of fat-free potato chips, which
were cooled and packaged. The potato chips were evaluated by
trained sensory professionals and were noted to have a pleasant
cooked potato flavor, golden color, and light crisp texture.
Example 23
Larger Size, Puffed Potato Strips Made by Steam Blanch Instead of
Immersion Blanch, Lincoln Impingement Finish
[0133] Yukon Gold potatoes were peeled and cut slices approximately
2 mm thick. These slices were then cut into strips approximately 6
mm wide, 6 cm in length. Approximately 750 grams of the raw potato
strips were rinsed under 65.degree. F. running water for 15
seconds. Then the rinsed strips were held in a solution containing
500 grams water (43.degree. C./110.degree. F.), 5 grams bacterial
amylase (Lot No. ALI05175-04, American Laboratories, Inc.), 5 grams
calcium chloride (32% solution Calcium Chloride from DSM Food
Specialties) for 3 minutes. The enzyme treated potato strips were
drained, then blanched using steam in a M-6 Dixie Vegetable
Blancher/Cooler (Dixie Canning Company, Athens Ga., 30603) for 30
seconds. The hot steam blanched potato strips were placed directly
on perforated aluminum tray and put into an Impingement oven
(Impinger.RTM. I, Model No. 1240 from Lincoln Food Service
Products, Inc., Fort Wayne, Ind.) set at 135.degree. C./275.degree.
F. Oven belt speed was set at 27 minutes. Every 5 minutes, the tray
was shaken to stir the potato strips to allow for even drying. The
process yielded approximately 129 grams of fat-free potato strips,
with a light texture, approximately 90% of the strips puffed into
almost cylindrical shape, giving them the appearance of crispy
French fries. The fat-free potato strips were judged by trained
sensory professionals to have a very rich buttery flavor, crisp
light texture and appetizing appearance.
Example 24
Impingement Oven for Initial Dry, then Pulsing Fluid Bed Dryer for
Final Regular Fat Free Potato Chips
[0134] Atlantic Variety chipping potatoes were peeled and sliced
using a Dito Dean vegetable slicer with a C2 blade, to achieve
slice thicknesses of approximately 1.60 mm. After slicing, 1000
grams of the raw potato slices were rinsed for under 65.degree. F.
running water for 15 seconds. Then the rinsed slices were held in a
solution containing 1000 grams water (43.degree. C./110.degree.
F.), 10 grams bacterial amylase (Lot No. ALI05175-04, American
Laboratories, Inc.), 10 grams calcium chloride solution (32%
solution Calcium Chloride from DSM Food Specialties) for 3 minutes.
The enzyme treated potato slices were drained, then blanched in
87.degree. C./190.degree. F. water containing 2% Cargill Sea Salt
(3000 g cold water, plus 60 g. salt) for 1 minute before draining.
The blanched potato slices were placed directly on the belt of and
impingement oven set at 176.degree. C./350.degree. F., and dried
for 1 minute to reduce the moisture content to 50%, then the chips
were layered to a bed depth of 3 inches, then placed into an
industrial Aeropulse.RTM. pulsed-air fluid bed processor (Aeroglide
Corporation, Raleigh, N.C. 27626) set at 148.degree. C./300.degree.
F. for 5 minutes. The process yielded approximately 200 grams of
fat free potato chips, which were cooled and packaged. The potato
chips were evaluated by trained sensory professionals and were
noted to have a pleasant cooked potato flavor, golden color, and
light crisp texture.
Example 25
Wavy or Ripple Fat-Free Potato Chips
[0135] Atlantic variety potatoes were peeled and sliced on a
mandolin corrugated blade so that slices approximately 2 mm height
at the thickest point and 1.65 mm at the thinnest point were formed
very similar in appearance, shape and thickness to potato chips
marketed currently under the names of "wavy" or "Ripple" chips.
After slicing, 500 grams of these the raw potato slices were rinsed
for under 65.degree. F. running water for 15 seconds. Then the
rinsed slices were held in a solution containing 500 grams water
(43.degree. C./110.degree. F.), 5 grams bacterial amylase (Lot No.
ALI05175-04, American Laboratories, Inc.), 5 grams calcium chloride
solution (32% solution Calcium Chloride from DSM Food Specialties)
for three minutes. The enzyme treated potato slices were drained,
then blanched using steam in a M-6 Dixie Vegetable Blancher/Cooler
(Dixie Canning Company, Athens Ga., 30603) by exposing the slices
directly to steam for 30 seconds at atmospheric conditions.
Blanched potato slices were placed directly on and put into an
impingement oven (Impinger.RTM. I, Model No. 1240 from Lincoln Food
Service Products, Inc., Fort Wayne, Ind.) set at 140.degree.
C./285.degree. F. Oven belt speed was set at 24 minutes. The
process yielded approximately 110 grams of fat-free potato chips,
which were then cooled and packaged. The potato chips were
evaluated by trained sensory professionals and were noted to have a
pleasant cooked potato flavor, golden color, and light crisp
texture.
Example 26
Puffy Potato Chips
[0136] Yukon Gold potatoes were peeled and cut into slices
approximately 2 mm thick. Approximately 750 grams of these raw
potato strips were rinsed under 65.degree. F. running water for 15
seconds. Then the rinsed slices were held in a solution containing
500 grams water (43.degree. C./110.degree. F.), 5 grams bacterial
amylase (Lot No. ALI05175-04, American Laboratories, Inc.), 5 grams
calcium chloride (32% solution Calcium Chloride from DSM Food
Specialties) for 3 minutes. The enzyme treated potato slices were
drained, then blanched in 87.degree. C./190.degree. F. water
containing 2.5% Cargill Sea Salt (3000 g water, plus 75 g salt) for
1 minute 30 seconds before draining. Blanched potato slices were
placed directly on a wire belt and ran through an Impingement oven
(Impinger.RTM. I, Model No. 1240 from Lincoln Food Service
Products, Inc., Fort Wayne, Ind.) set at 140.degree. C./285.degree.
F. Oven belt speed was set at 9 minutes for the initial pass, then
the potato slices were ran through again for 6 minutes. The process
yielded approximately 135 grams of fat-free potato chips, with a
light texture, approximately 90% of the chips puffed into a thicker
shape with a pillow-like appearance and hollow center. These puffy,
fat-free potato chips were judged by trained sensory professionals
to have a very rich buttery flavor, crisp light texture, and
appetizing appearance.
Example 27
Fat-Free Sweet Potato Chips
[0137] Organic Japanese Sweet Potatoes were peeled and sliced into
slices approximately 1.8 mm thick. After slicing, 1000 grams of
these raw sweet potato slices were rinsed under 65.degree. F.
running water for 15 seconds. Then the rinsed slices were blanched
in 87.degree. C./190.degree. F. water containing 2% Cargill Sea
Salt (2000 g cold water, plus 40 g salt) for 1 minute 30 seconds
before draining. Blanched slices were placed directly on chain belt
of impingement oven (Impinger.RTM. I, Model No. 1240 from Lincoln
Food Service Products, Inc., Fort Wayne, Ind.) set at 140.degree.
C./285.degree. F. Oven belt speed was set at 14 minutes. The
process yielded approximately 230 grams of fat-free sweet potato
chips, which were cooled and packaged. The sweet potato chips were
evaluated by trained sensory professionals and were noted to have a
very pleasant sweet flavor, bright orange color, and light crisp
texture.
Example 28
Use of Rotary or Rotary Drum Dryer as the First Step of the Cooking
Process
[0138] Chipping potatoes were washed, peeled, sliced to
approximately 1.55 mm thickness, and then washed and exposed to a
solution containing bacterial amylase (Lot No. ALI05175-04,
American Laboratories, Inc.), and calcium chloride solution (32%
solution Calcium Chloride from DSM Food Specialties). Next the
enzyme treated potato slices were drained followed by blanching at
87.degree. C./190.degree. F. water containing 2% Cargill sea salt
before then again draining. Then the blanched potato slices were
cooled and stored. Several samples of the sliced potatoes were
tested on an Omni Mark moisture analyzer available from Denver
Equipment Company before and after the dehydrating step. The
analyzer indicated that raw enzyme treated potato slices had a
moisture level between 80% and 85% after blanching and just prior
to drying.
[0139] The sliced potatoes were then placed in bulk form Inside a
rotary drum dryer provided by Spray Dynamics and partially
dehydrated in mass quantity at a temperature of about 300.degree.
F. for about 10 minutes. The partially dehydrated slices were then
removed from the rotary dryer and visually tested for quality,
color, texture, breakage, smelt and flavor. Surprisingly, all
slices had an excellent texture, color, flavor, smell, and, even,
more surprisingly minimal, if any, breakage, sticking or any other
visual impairment was noticed. The drying was uniform and all
slices had similar color and a consistent level of dehydration.
[0140] The test was repeated for several times at temperatures
ranging between about 275.degree. F. and about 350.degree. F. and
for periods as low as about 5 and as high as about 14 minutes. The
visual results were all surprisingly good as in the first trail and
consistent among trials.
[0141] Moisture levels following the dehydrating processes of
various lengths between about 5 to about 14 minutes produced snack
food slices with a moisture content ranging between about 40% and
about 70%.
[0142] To further test the efficacy of the teachings of the present
invention an additional test was conducted using the rotary drum
dryer available from Spray Dynamics. Potato slices without enzyme
treatment were placed in the drum dryer in the same manner as
explained above and partially dehydrated at 300.degree. F. for
periods as high as about 12 minutes. The process consistently
produced less preferable results as, following the dehydrating
step, the slices had a color, texture, quality, flavor and odor
deemed to be commercially undesirable. The drying was inconsistent.
Some slices had dried out to a hard consistency similar to and/or
as of dehydrated potatoes. Other slices, however, were totally or
partially wet or even burnt totally or around the edges. It is
believed that food products containing high levels of starch will
be greatly enhanced by using an enzyme treatment as the enzyme
treatment possibly breaks down the sugars on the surface of the
food slice.
[0143] Then, the pretreated dehydrated potato slices of potatoes
processed in accordance with the teachings of the present invention
were used to produce potato chips that have same texture,
crunchiness, color, taste and mouth feel as conventionally deep
fried potato chips. Pretreated potato slices cooked at a
temperature of about 300.degree. F. for about 8 minutes containing
approximately 51% moisture (Pretreated Dehydrated Potato Slices)
were used in the following tests.
Example 28A
[0144] Approximately 5,000 grams of the Pretreated Dehydrated
Potato Slices were poured onto the opening conveyer belt of a
fluidized bed dryer available from Witte Company and were further
massively subjected to heat at a temperature of about 325.degree.
F. for about 6 minutes. The air velocity was between about 300 to
about 350 cfm. The cooked Pretreated Dehydrated Potato Slices were
then left to cool down to ambient temperature (80.degree. F.). The
resulting potato chips, included some air pockets/blistering
resembling conventional fried chips, and had excellent texture,
mouth feel, taste, color, and crunchiness totally commensurate with
or better than that of their counterpart potato chips that are made
through conventionally deep frying methods. The trial yielded
approximately 1,990 grams of fat free potato chips.
Example 28B
[0145] Approximately 1,500 grams of the Pretreated Dehydrated
Potato Slices were placed in a multiple layer configuration on the
conveyer belt of an Industrial Air Force.RTM. impingement oven
(Heat and Control Company, Hayward, Calif. 94545) creating a bed
depth of 1 inch, then processed for 5.5 minutes at 148.degree.
C./300.degree. F. The process yielded approximately 660 grams of
fat-free potato chips, which were cooled and packaged. The potato
chips were evaluated by trained sensory professionals and were
noted to have a pleasant cooked potato flavor, golden color, and
light crisp texture.
Example 28C
[0146] Approximately 2,000 grams of the Pretreated Dehydrated
Potato Slices were processed further in a multi layer format using
an industrial Aeropulse.RTM. pulsed-air fluid bed processor
(Aeroglide Corporation, Raleigh, N.C. 27626) set at 148.degree.
C./300.degree. F. for 5 minutes. The process yielded approximately
830 grams of fat free potato chips, which were cooled and packaged.
The potato chips were evaluated by trained sensory professionals
and were noted to have a pleasant cooked potato flavor, golden
color, and light crisp texture.
Example 28D
Approximately 1000 grams of the Pretreated Dehydrated Potato
[0147] Slices were further processed using a convection oven (Model
#6203, Lincoln Steam'r Oven, Lincoln Food Service Products, Fort
Wayne, Ind.). The potato slices were placed on perforated trays and
cooked in the oven for 12 minutes at 148.degree. C./300.degree. F.
until the products were fully dried. The trial resulted in
approximately 400 grams of finished fat free potato chips. The
potato chips were evaluated by trained sensory professionals and
were noted to have a pleasant cooked potato flavor, golden color,
and light crisp texture.
Example 28E
[0148] Approximately 2000 grams of the Pretreated Dehydrated Potato
Slices were further processed in a stationary tray dryer (National
Dryer Machinery Company, Philadelphia, Pa.), by placing the potato
slices in a layer approximately 3/4 inch deep and drying for 16
minutes at a temperature of 148.degree. C./300.degree. F. The trial
resulted in approximately 810 grams of fat free potato chips. These
chips were evaluated by trained sensory professionals and were
noted to have a bright golden color, excellent potato chip flavor
and light crisp texture.
Example 29
Impingement Oven for Initial Dry, then Vibrating Fluidized Bed
Dryer for Final Regular Fat Free Potato Chins
[0149] Snowden variety chipping potatoes were washed and sliced
using a Ditto Dean vegetable slicer with a C3 blade, to achieve
slice thicknesses of approximately 1.60 mm. After slicing, 3.95
lbs. of the raw potato slices were rinsed for under 65.degree. F.
running water for 15 seconds. Then the rinsed slices were held in a
solution containing 3000 grams water (43.degree. C./110.degree.
F.), 30 grams bacterial amylase (Lot No. AULI05175-04, American
Laboratories, Inc.), 30 grams calcium chloride solution (32%
solution Calcium Chloride from DSM Food Specialties) for 3 minutes.
The enzyme treated potato slices were drained, then blanched using
steam in a M-6 Dixie Vegetable Blancher/Cooler (Dixie Canning
Company, Athens Ga., 30603) for 40 seconds. The blanched potato
slices were placed directly on the belt of and Impingement oven set
at 176.degree. C./350.degree. F., and dried for 5 minutes to reduce
the moisture content to 36%, then the chips were layered to a bed
depth of 2 inches, then placed into an lab model vibrating fluid
bed processor (Carrier Vibrating Equipment, Inc., Louisville, Ky.
40213) with a drilled hole type plate, an dried/cooked at
160.degree. C./320.degree. F. for 2 minutes. The process yielded
approximately 1 pound of fat free potato chips, which were cooled
and packaged. The potato chips were evaluated by trained sensory
professionals and were noted to have a pleasant cooked potato
flavor, golden color, and light crisp texture.
Example 30
Steam Blanch, then Vibrating Fluidized Bed Dryer for Entire Drying
Step on Fat Free Sweet Potato Chips
[0150] Common variety sweet potatoes were washed, peeled, and
sliced using a Ditto Dean vegetable slicer with a C3 blade, to
achieve slice thicknesses of approximately 1.80 mm. After slicing,
3.0 lbs. of the raw sweet potato slices were rinsed for under
65.degree. F. running water for 15 seconds. Then the rinsed slices
were drained and blanched using steam in a M-6 Dixie Vegetable
Blancher/Cooler (Dixie Canning Company, Athens Ga., 30603) for 50
seconds. The blanched sweet potato slices were rinsed under cold
water spray for 3 minutes, drained then stored in plastic bags in a
cooler overnight. The blanched sweet potato slices were layered to
a bed depth of 2 inches in an lab model vibrating fluid bed
processor (Carrier Vibrating Equipment, Inc., Louisville, Ky.
40213) with a drilled hole type plate, and dried/cooked at
176.degree. C./350.degree. F. for 4 minutes. Temperature of the
processor was then reduced to 160.degree. C./320.degree. F. and
product was cooked for an additional 2 minutes before the processor
temperature was reduced to 148.degree. C./300.degree. F. for
additional two minutes of final drying/cooking time. The sequential
temperature reductions allowed for a controlled drying process,
maintaining product temperature below 148.degree. C./300.degree. F.
at the final stages of drying when no evaporative cooling was
taking place to prevent product browning and controlling
caramelization of natural sugars present in the product. This
controlled process yielded approximately 0.75 of fat-free sweet
potato chips, which were cooled and packaged. The sweet potato
chips were evaluated by trained sensory professionals and were
noted to have a very pleasant sweet flavor, bright orange color,
and light crisp texture.
[0151] The above process was repeated a number of times with sweet
potatoes that were additionally treated with calcium chloride,
amylase enzyme and the combination of the two yielding desired
products with great color, texture and taste.
[0152] Additionally, pears, apples, squash, and a varieties of
carrots including yellow, orange, white and purple carrots were
processed in similar procedures as above all resulting in excellent
products having great taste, color and texture.
Example 31
Steam Blanch, then Vibrating Fluidized Bed Dryer for Entire Drying
Step on Fat Free Potato Sticks
[0153] Common Russet potatoes were washed, peeled, and sliced using
a Ditto Dean vegetable slicer with an AS-4 blade, to achieve
julienne slice or stick shape with 2.0 mm square, and average
length of 8 cm. After slicing, 2.80 lbs. of the raw potato sticks
were rinsed for under 65.degree. F. running water for 15 seconds.
Then the rinsed potato sticks were drained, held in a solution
containing 3000 grams water (43.degree. C./110.degree. F.), 30
grams bacterial amylase (Lot No. ALI05175-04, American
Laboratories, Inc.), 30 grams calcium chloride solution (32%
solution Calcium Chloride from DSM Food Specialties) for 3 minutes.
The enzyme treated potato sticks were drained, and blanched using
steam in a M-6 Dixie Vegetable Blancher/Cooler (Dixie Canning
Company, Athens Ga., 30603) for 55 seconds. The blanched potato
sticks were rinsed under cold water spray for 3 minutes, drained,
then potato sticks were marinated in a in a solution containing
1000 g. water, 75 grams of tomato juice, 10 grams lemon juice, 10
grams carrot juice plus 10 grams of salt in a cooler overnight. The
following day, the marinated potato sticks were drained and layered
to a bed depth of 2 inches in an lab model vibrating fluid bed
processor (Carrier Vibrating Equipment, Inc., Louisville, Ky.
40213) with a drilled hole type plate, and dried/cooked at
160.degree. C./320.degree. F. for 6 minutes. Temperature of the
processor was then reduced to 148.degree. C./300.degree. F. and
product was cooked for an additional 2 minutes before the processor
temperature was reduced to 140.degree. C./285.degree. F. for
additional two minutes of final drying time. The sequential
temperature reductions allowed for a controlled drying process,
maintaining product temperature below 148.degree. C./300.degree. F.
at the final stages of drying when no evaporative cooling was
taking place to prevent product browning and controlling
caramelization of natural sugars present in the product. This
controlled process yielded approximately 0.60 of fat-free potato
sticks, which were cooled and packaged. The resulting product was
very bright golden in color, with a pleasant, slightly salty
buttery potato flavor and having an excellent crispy light
texture.
Example 32
Fat-Free Tortilla Chips Using Vibrating Fluidized Bed Dryer for
Final Cooking
[0154] Commercial 6 inch diameter white corn tortillas were
purchased at the local grocery store, each tortilla was cut Into
eight wedges or triangles. Approximately 500 grams of these
tortilla pieces were held in a solution containing 3000 grams water
(43.degree. C./110.degree. F.), 30 grams bacterial amylase (Lot No.
ALI05175-04, American Laboratories, Inc.), 30 grams calcium
chloride solution (32% solution Calcium Chloride from DSM Food
Specialties) for 3 minutes. The enzyme treated tortilla pieces were
drained, then layered to a bed depth of 11/2 inches and placed into
a lab model vibrating fluid bed processor (Carrier Vibrating
Equipment, Inc., Louisville, Ky. 40213) with a drilled hole type
plate, and dried/cooked at 160.degree. C./320.degree. F. for 7
minutes. The process yielded approximately 200 grams of tortilla
chips, which were cooled and packaged. The tortilla chips were
evaluated by trained sensory professionals and were noted to have a
pleasant cooked tortilla flavor, a very light golden color, smooth
appearance, and light crisp texture. When compared with a sample
processed in a similar manner but without the enzyme treatment, the
sample processed using the procedure of the present invention was
noted to be much lighter in texture and exhibited a lighter crunch
and crispiness. The sample processed without enzyme treatment but
rather held in just water for 3 minutes was tough and less crispy
than the one which was produced using the process of the present
invention.
Example 3
Crispness Tests
[0155] Vegetable snack chips are favored for their crispy, crunchy
bite which is particularly characteristic of traditional fried
chips. Crispness and crunchiness can be quantified with an
instrument that records the force required to break chips as well
as their stiffness prior to failure. The ratio of increased
resistance to increased flexure or deformation is Young's modulus
(also called the elastic modulus). Vickers and Christensen
(Vickers, Z. M. and Christensen, C. M. 1980. Relationship between
sensory crispness and other sensory and instrumental parameters.
Journal of Texture Studies 11: 291-307.) found that, of
instrumental measurements, Young's modulus had the highest
correlation to crispness in foods. These authors showed that it is
also helpful to record the sound made when the chip breaks since
they found crispness was very closely related to loudness during
fracture. The importance of snack food sound is underscored by
Vickers' (Vickers, Z. M. 1983. Pleasantness of Food Sounds. Journal
of Food Science 48: 783-786.) observation that pleasantness of food
sounds was highly correlated with descriptors `crisp` and
`crunchy.`
[0156] Accordingly, to be perceived as crisp and crunchy, snack
food products need to have an adequate stiffness, (as reflected in
Young's modulus) and to emit at least a certain level of sound upon
breaking. At the same time, snack food products should not require
so great a force as to cause mouth pain or Injury. To evaluate
crispness, samples were fractured on a TA.XT Plus Texture Analyzer
(Stable Microsystems, Godalming, U.K.) fitted with a TA-101 Chip
Rig and a 5 kg load cell. The TA-101 rig has 2 cm diameter by 2 cm
tall pipe which supports the chip in a horizontal position. A 5 mm
ball descended at 1 mm/sec until 5 g resistance was sensed, then it
continued 30 mm and the force of resistance was recorded as the
chip bent and fractured. A Stable Microsystems Audio Envelope
Detector was used to record the sound produced during fracture.
[0157] To demonstrate the crispness/crunch of various snack
products, representative samples were analyzed to measure the force
required and acoustic levels resulting from fracturing chips. The
analysis methods consisted of testing samples of chips listed in
Table 3 below, labeled A through M, with samples A, B, C, D, L and
M being produced in accordance to the present invention as
described in examples 28, 24, 25, 26, 27 and 5 respectively, with
retail samples E, F, G, H, I J, and K purchased at a local grocery
store in Lincoln, Nebr. Representative chips were selected from
each sample, handled, and analyzed in a consistent manner to obtain
the data presented in Tables 3, 4, 5 and 6.
[0158] From each sample of about 25 chips, 9 chips were selected
for the test The more uniform chips were selected for measurement,
because chips were variable in thickness and blistering. The nine
selected chips were fractured and measurements were made of the
force required to fracture each chip as the probe broke each chip
while moving toward the chip at a uniform speed of 1 mm/second.
Exponent software was used to generate a plot of force (Newtons)
against distance (mm), and to determine (1) the initial slope,
which is Young's Modulus, as discussed above, (2) the peak force
required to fracture the chip and (3) peak loudness upon fracture
of the chip. Excel Spreadsheet software was used to calculate
means, standard deviation and coefficient of variation. Prior to
this objective testing, samples A, B, C, D, L and M were all tasted
and found to be favorably crisp and crunchy and samples E through K
were determined to be within the indicated shelf life on the
original package.
[0159] Graphs plotting force (N) against distance (mm) traveled by
the probe were generated for each force measurement. Each of these
plots depict a series of increases in resistance to applied force
as the chip bends under pressure from the probe just prior to
fracture. The probe is moving toward the chip at a constant
velocity of 1 mm per second (1 mm/sec). In each case, the increase
in resistance to applied force is followed by a sudden drop in
resistance to such force as the chip breaks. In most cases, the
chips fracture and break in a series of fractures. The first
fracture, however, is the focus for determining the peak force
required to fracture the chip. The peaks created in this way,
characterize the chip's texture, i.e., how much does the chip
resist bending before breaking, how far will it bend before
breaking and at what distance and force does it break. These
quantities `fingerprint` fracture properties and their crispness
and crunchiness. The sudden loss in resistance (after the force
peaks) is accompanied by a recorded sound event since the chip is
set vibrating by the sudden loss in deformation and stress. As
noted above, typical graphs include 2 to 4 major force peaks and a
corresponding number of sound peaks. The slope prior to each peak
estimates the aforementioned Young's modulus, which is a good
estimate of crunchiness. Since the samples tested were all crisp,
any of the chips with an average Young's modulus greater than 3.5
N/mm are clearly crisp. In accordance with the present invention,
it is preferable to product a snack food product with a Young's
modulus of about 3.5, more preferably about 4.0, even more
preferably 4.5, and even more preferably about 5.0 N/mm. It is also
preferable to have a snack food product that will fracture at about
12, preferable about 10 and more preferably about 9 N of force
applied to the chip so that the snack food product is crunchy but
does not require so much force so that is hurts to eat the
product.
[0160] The results of testing are provided in Tables 3-6 below. The
resulting sound levels listed in Table 5 below do not have units as
they are a relative number.
TABLE-US-00003 TABLE 3 Mean average for greatest force, sound and
initial Young's modulus from the data presented in Tables 4-6.
Young's Force Peak Modulus Sample Peak (N) Sound (N/mm) A--Thin
chip of the present invention 3.95 4097 13.7 B--Wavy chip of the
present invention 4.58 3744 8.5 C--Puffy chip of the present
invention 6.65 5968 19.7 D--Thick chip of the present invention
7.12 4139 15.7 E--Lays .RTM. Classic 3.19 927 5.7 F--Lays .RTM. Fat
Free with OLESTRA .TM. 2.59 1142 4.2 G--Lays .RTM. Kettle Cooked
Chips 5.14 1616 10.8 H--Kettle .TM. Chips (Kettle Brand) 7.45 1447
14.2 I--Low Fat Kettle .TM. Krisp 5.65 23229 9.9 J--Kettle .TM.
Brand Bakes 6.23 3886 10.2 K--Terra .RTM. Yukon Gold 9.06 10513
18.3 L--Sweet potato chips of the present 8.77 6943 18.9 invention
M--Beet chips of the present invention 3.62 3758 7.3
TABLE-US-00004 TABLE 4 Maximum Force (N). % Coefficient of REP 1
REP 2 REP 3 REP 4 REP 5 REP 6 REP 7 REP 8 REP 9 MEAN Variation A
1.20 3.77 1.62 2.84 7.39 3.45 5.41 5.29 4.53 3.95 50% B 4.05 5.65
3.64 5.09 2.19 2.68 5.89 4.64 7.38 4.58 36% C 7.47 6.78 2.99 8.60
8.55 4.63 5.51 8.04 7.30 6.65 29% D 8.14 8.05 7.11 7.76 4.86 6.38
10.37 7.63 3.79 7.12 27% E 2.29 5.03 2.54 2.35 3.92 5.96 1.52 2.51
2.60 3.19 46% F 2.77 1.74 2.19 2.54 1.97 2.80 4.32 2.31 2.71 2.59
29% G 4.65 4.30 4.88 3.56 6.44 4.21 4.51 5.81 7.89 5.14 26% H 9.69
7.43 8.67 9.85 5.87 8.16 4.41 6.64 6.37 7.45 24% I 5.56 3.73 6.55
4.19 4.50 8.97 8.72 3.56 5.03 5.65 36% J 2.06 7.56 6.94 11.94 6.39
2.95 8.12 4.00 6.16 6.23 48% K 11.68 9.37 10.75 10.88 7.20 5.97
11.10 8.75 5.87 9.06 25% L 8.88 8.88 11.22 7.25 10.10 6.35 7.59
6.53 12.13 8.77 23% M 2.73 2.02 3.15 4.81 3.64 3.93 5.74 3.30 3.28
3.62 31%
TABLE-US-00005 TABLE 5 Loudness. % Coefficient of REP 1 REP 2 REP 3
REP 4 REP 5 REP 6 REP 7 REP 8 REP 9 MEAN Variation A 1587 4402 2229
2140 6902 4266 7714 4349 3287 4097 51% B 4427 3933 4247 4741 1728
3965 5592 2412 2656 3745 33% C 6618 7134 5599 7986 8598 5215 2246
5510 4813 5969 32% D 5211 4778 7179 4753 2436 4804 4158 2361 1577
4140 42% E 1293 915 634 583 1198 1432 875 633 782 927 34% F 389 661
634 1264 1299 1284 2544 1202 1008 1143 55% G 2269 1030 880 1462
2242 810 1355 1825 2674 1616 42% H 1549 1877 819 1132 1839 1571
1181 1041 2020 1448 29% I 5558 4560 8370 1698 5257 7193 4318 3479
4537 4997 39% J 1538 2237 4534 5610 1539 4445 6575 4060 4441 3887
45% K 506 1409 1175 1626 1136 935 630 938 1107 1051 33% L 7600 6965
1175 7909 5915 4004 8198 6015 4132 6944 34% M 2806 3791 2668 3527
3171 5403 6226 2593 3638 3758 33%
TABLE-US-00006 TABLE 6 Young's Modulus (N/mm). % Coefficient of REP
1 REP 2 REP 3 REP 4 REP 5 REP 6 REP 7 REP 8 REP 9 MEAN Variation A
11.3 18.0 22.2 5.8 6.5 16.0 11.8 15.6 16.5 13.7 39% B 11.3 8.5 9.6
4.5 5.0 10.6 6.9 8.0 12.4 8.5 32% C 19.1 18.4 8.9 28.1 18.6 22.7
17.7 27.2 16.5 19.7 30% D 14.3 16.0 18.3 16.6 18.1 7.1 22.0 14.0
14.8 15.7 26% E 4.9 16.4 5.0 4.1 6.3 5.5 1.1 3.6 4.1 5.7 75% F 4.8
2.1 5.5 3.1 3.7 6.2 1.0 6.9 4.5 4.2 46% G 11.3 13.9 9.0 6.8 21.2
3.1 6.5 8.3 17.0 10.8 53% H 25.4 19.8 15.8 12.8 13.5 11.9 8.7 13.6
6.6 14.2 40% I 8.2 2.2 15.0 3.8 21.0 14.4 15.9 3.4 5.8 9.9 68% J
3.8 11.9 8.8 13.4 3.6 10.2 23.6 7.2 9.0 19.2 59% K 21.9 4.7 27.6
22.1 30.2 12.7 24.1 19.2 2.2 18.3 53% L 25.6 1.0 22.0 9.8 26.7 23.9
17.4 16.6 26.8 18.9 46% M 7.0 6.0 5.6 11.2 5.2 7.8 10.2 6.6 6.4 7.3
28%
[0161] While the invention has been described in conjunction with
specific embodiments thereof, it is evident that many alternatives,
modifications and variations will be apparent to those skilled in
the art in light of the foregoing description. Accordingly, it is
intended to include all such alternatives, modifications and
variations as set forth within the spirit and scope of the appended
claims.
* * * * *